Shell Oil Educational Outreach Program

In 2016, EC&MW, Inc. designed and engineered this unique aluminum gantry crane for Shell Oil Company to support one of its educational outreach programs. The gantry was used during demonstrations at universities, engineering schools, and industry events to showcase an innovative, highly fuel-efficient concept vehicle while encouraging future engineering students to consider careers with Shell.

The vehicle itself was a fully functional, drivable prototype that traveled throughout the country for exhibitions and demonstrations. Because the entire display needed to be transported from venue to venue, the aluminum gantry was designed with folding legs for compact shipping and quick assembly.

Project Requirements

The customer required a custom gantry crane that would:

• Support a nationwide traveling educational exhibit.
• Fold for compact transportation and storage.
• Assemble quickly at universities, trade shows, and engineering events.
• Provide a 1,000-pound rated lifting capacity with the appropriate factor of safety.
• Assist personnel entering and exiting an extremely compact concept vehicle.

Custom Design Features

The gantry was designed with folding aluminum legs, allowing it to be transported efficiently between exhibition locations while minimizing setup time. Since the crane was intended to remain stationary during demonstrations, it was built without casters and featured a fixed height of seven feet under the I-beam.

Although many people assumed the crane was designed to lift the vehicle itself, its actual purpose was far more unique.

Custom Lifting Solution

To maximize fuel efficiency, Shell’s concept vehicle was designed around a single driver. The cockpit was extremely compact, leaving very little clearance around the driver’s legs, waist, shoulders, and upper body. Entering and exiting the vehicle could therefore be difficult, particularly if the driver became lodged within the confined compartment.

To address this challenge, Shell developed a specialized loading and unloading system centered around the aluminum gantry crane. The driver wore a body harness connected to a custom rope-and-pulley system mounted to the gantry. It is important to note that this was not a fall-protection system. Its sole purpose was to provide lifting assistance while entering or exiting the vehicle when needed.

EC&MW incorporated a three-sheave mechanical advantage pulley system, similar in principle to those used in aerial performance productions such as Cirque du Soleil. This arrangement allowed an attendant to provide smooth, controlled lifting assistance with very little effort.

More importantly, if the driver became caught or hung up while entering or exiting the cockpit, the system could immediately relieve the driver’s weight and just as quickly lower them back into position. A conventional chain hoist or chain fall would not have provided the same level of smooth, responsive control required for this application.

If memory serves correctly, the designated driver weighed less than 120 pounds, further supporting the vehicle’s extreme fuel-efficiency objectives.

Engineering Innovation

While the crane’s rated lifting capacity was only 1,000 pounds, the engineering challenge was not about lifting heavy equipment—it was about safely assisting a person within an extremely confined space while maintaining complete control throughout the movement.

The project required:

• Lightweight aluminum construction for portability.
• Compact folding legs for nationwide transportation.
• Fast setup and teardown at multiple event locations.
• Smooth, controlled lifting assistance for personnel.
• A custom pulley system specifically engineered for occupant safety.

Project Summary

This project remains one of the most innovative and unconventional applications for an aluminum gantry crane engineered by EC&MW. Rather than lifting machinery or industrial equipment, the crane served as a custom-designed personnel loading and unloading system for a highly specialized concept vehicle. It demonstrates how thoughtful engineering and custom design can solve unique challenges while providing safe, reliable solutions far beyond traditional material handling applications.