Client Overview
W. Christie (Industrial) Ltd is a UK engineering business with over 50 years of experience in industrial bolting and bespoke engineered equipment for demanding industrial environments. W. Christie is continually expanding and diversifying its product range through the integration of innovative technologies, providing solutions for maintenance and engineering teams across a wide range of applications and industries.
Challenges and project scope
To support rail maintenance operations, W. Christie’s client required a bespoke, powered scissor-lift vehicle capable of transporting heavy underframe components beneath trains while operating within the constraints of a rail depot environment.
Lancereal was initially approached by W. Christie to supply a transaxle and associated drive solution for the vehicle to enable it to lift, lower and move forwards and backwards.
As the project developed, the requirements expanded which introduced several control-system challenges, such as:
Drive control: Providing controlled forward and reverse movement with a speed option through the electric drivetrain.
Lifting and load management: Developing control logic to support the lifting operation and monitor hydraulic pressure to determine the loaded condition of the vehicle.
Safety-related control functions: Incorporating operational interlocks, stopping conditions and speed limitations to support controlled machine operation.
System communication: Coordinating signals between the drive controller and CAN expansion module, including the communication of load-status information from the sensors.
Bespoke operating functionality: Implementing application-specific speed settings, emergency reverse behaviour and proximity-based stopping logic to meet the machine's operational requirements.
These requirements meant that the project needed more than a standalone drivetrain. It required a complete powertrain package and bespoke control software, tailored to the vehicle's operating conditions. A further consideration was weight, as the completed machine was required to handle a total lifted load of approximately 5 tonne, including a 2.5 tonne working load limit.
Solution
Drawing on its experience in electric powertrain engineering and embedded control software, Lancereal developed and supplied a complete drivetrain and control package for the maintenance scissor lift.
The solution incorporated an induction motor, transaxle, Curtis motor controller, operator display, CAN expansion module and bespoke application software to accommodate the evolving control requirements.
All of the challenges and complexities introduced from the extended scope were accommodated in the final solution which drew heavily on Lancereal's software development capabilities.
In addition, Lancereal conducted on-site commissioning, resolving installation and technical challenges, and bringing the complete system into operation.
This combined hardware and software approach enabled Lancereal to respond to changing project requirements while maintaining a coordinated control architecture across the vehicle's drivetrain and hydraulic functions.
Outcomes
The bespoke scissor lift vehicle was successfully delivered to the end customer and is operational in a rail maintenance environment.
The project demonstrates Lancereal's ability to develop a complete powertrain and control solution around an initially limited drivetrain requirement, combining electrical, mechanical and software expertise to meet the needs of a specialised application.
Following the success of the project, further bespoke variations of the vehicle are in development and may include further variants such as:
- Increased lifting capacity
- Greater vehicle length
- Higher jacking height
To see the type of projects W. Christie undertakes for the rail industry click here. And to explore the wider scope of their capabilities visit their site.
The project highlights Lancereal's capabilities as a full-service systems integration partner, providing tailored powertrain hardware, embedded software development and engineering support for demanding off-highway and rail maintenance applications.
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