Moving two tons without the strain
Date: 21/04/2026
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Handling multi-ton data servers in narrow aisles presents both ergonomic and operational challenges. Discover how an electrically assisted mobility solution eliminates operator strain while improving precision and safety.
The customer’s challenge:
The customer, a major manufacturer of trolleys for data centre corporations, required a reliable electrically assisted mobility solution to move heavy data servers weighing up to 2 tons. Their existing trolley used castor wheels with a lifting mechanism to raise servers, but movement still relied on manual force, causing significant musculoskeletal strain on workers.
The initial system in place:
Our initial visit focused on analysing the existing setup, including trolley design, manoeuvrability, and operational time requirements. The trolleys operated in tight spaces between rows of servers, requiring precise positioning of the lifting mechanism beneath each unit. Due to the servers’ size obstructing visibility, one worker pushed from one end while another guided direction from the opposite end, making coordination difficult. This process, repeated multiple times daily, led to increased physical strain.
The solution we provided:
The challenges were clear: the solution needed precise control for navigating tight spaces, while allowing manual alignment under servers. It also required a safety system enabling the guiding worker to stop the trolley when needed.
The IDEC ez-Wheel Assist Wheel Drive met these requirements by delivering up to 1 ton per wheel, enabling a total load capacity of 2 tons with two units. Dual independent controllers ensured smooth manoeuvrability and free movement when unpowered. Integrated I/O supported power controls and E-stops, cutting power or engaging electromechanical brakes for safety. Powered by a heavy-duty, hot-swappable 15 Ah battery, the system ensured extended uptime. The final prototype was rigorously tested under maximum load to meet all requirements.
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