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As-builtRev C
Case Study

AI-Guided Trolley Loader

Mechatronics Engineer ยท BigSis (Zyzzle Ltd), UK
Problem

Manual trolley loading across 63 trays was labour-intensive and inconsistent, limiting throughput and scalability.

Approach
  • Designed a multi-channel channeliser and belt-driven shuttle conveyor for precise tray positioning
  • Integrated an AI vision system to detect load size and dynamically regulate fill level per tray
  • Engineered secure locking to dock and stabilise the trolley, with multiple flow-control gates to balance distribution
Result

Full automation of multi-tray loading with AI-controlled fill accuracy, cutting manpower requirements while improving throughput and handling stability.