The brief - Rebuilding an unusable console
Rebuild a heavily damaged crane console within a budget far below that of a full replacement. The client wanted to reuse the existing electronics while providing better protection for use on site.
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Project · Lifting
Rebuilt crane console (Phase 1)
Refurbishing a heavily damaged crane console by reusing the existing electronics — for a budget far below that of a full replacement.
- Lifting equipment
- Repair
- FDM · Electronics
- March 2024
// ClientDGC Bois
// SectorLifting equipment
// TechnologyModelling · FDM · Electronics
// CompletedMarch 2024
Client's need
The need - Adapting the console to on-site constraints
The client supplied the original console in poor condition. Our brief: to analyse, carefully dismantle, clean and model the components in order to rebuild a new shell. The key constraints:
- Preserving the console's ergonomics
- Strength for professional use
- Effective protection of the electronics
Our goal – Starting again on solid foundations
This first phase made it possible:
- To understand how the console is used on site
- To assess the feasibility of rebuilding it
- To visualise the technical options through an initial modelling base
Our response
Meticulous dismantling and cleaning
The original console was partly in pieces, held together with tape. Dismantling proved delicate:
- Manual removal of the functional parts using precision tools
- Thorough cleaning (dust, grease)
- Photographs to document the layout
- Identification of the parts to replace (faulty or missing)
Modelling the electronic components
Once the components had been extracted:
- Each part was modelled in Fusion 360
- Creation of individual mounts for each component
- Design of an overall mount for the layout
- Sourcing of existing models online or manual measurement where needed
First design tests and adjustments
This phase gave rise to numerous partial prototypes to validate:
- The precise fit of the components
- The required tolerance clearances
- The strain-free routing of the cables
Conclusion
Repair rather than replace
A crane console refurbished around its existing electronics, for a fraction of the cost of a replacement. Extending the life of a piece of equipment, intelligently.
In pictures
The project in pictures
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