Remotely Operated Loading System: Design, Analysis, and Implementation

Abstract

Remotely operated systems are reshaping industrial automation by offering safer, more reliable alternatives to manual handling tasks. In this study, we present the conceptualization, structural evaluation, and practical implementation of a Remotely Operated Loading System (ROLS), developed to enhance precision and reduce physical strain during material insertion processes. The system integrates a cylindrical actuator (CYB1), a precision-aligned guide mechanism, and a spring-actuated mechanical latch, all controlled remotely through an RF-based interface. To ensure reliability and durability, Finite Element Analysis (FEA) was carried out using ANSYS 19.2. The analysis confirmed that critical components exhibit minimal deflection, optimal stress distribution, and maintain high safety margins under expected load conditions. The system demonstrates potential for safe, repeatable operations in settings like research laboratories, compact industrial units, and military applications.

Introduction

Manual loading tasks in industrial and laboratory settings often cause safety risks and inefficiencies, especially when inserting objects into narrow spaces. Fully automated systems are costly and complex, limiting their use in small and medium industries. This research introduces a semi-automated, remotely operated loading system that balances affordability, safety, and precision.

The system uses RF-based wireless control and incorporates carefully selected materials like AISI 1045 and 1020 steels for durability and fatigue resistance. Key components include a cylindrical body (CYB1), loading tube (LT1), alignment and screwing systems with servo motor and linear actuator, and support structures to ensure precise insertion.

Control is managed by an ESP32 microcontroller linked to an RF transceiver, servo motor, and linear actuator, all powered through a dedicated circuit. Finite Element Analysis confirms the system’s structural integrity under load, showing minimal deformation and stress within material limits.

This design reduces operator exposure to hazards, improves accuracy and consistency in loading, and offers a cost-effective alternative to fully automated systems, making it suitable for industrial, laboratory, and defense applications.

Conclusion

The remotely operated loading system successfully achieves its objectives of improving operator safety, enhancing loading accuracy, and reducing physical strain. Simulation results confirm that the system components perform well under expected loading conditions, with minimal deflection and safe stress levels. The remote control capability offers flexibility and usability in constrained environments. This study lays the groundwork for future development of fully autonomous loading tools incorporating AI, IoT, and predictive maintenance.

References

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Copyright

Copyright © 2025 Durvesh Rane, Vidhan Mhaske, Suyash Mane, Prajakta Jujam, Rasesh Nair, Yash Kamthe, Yash Shete, Ajay Kumar Vishwakarma. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.