Electric transfer cart is a kind of electric trolley system vehicle with rails in factories, mainly used in brick, shipyard, refractory, engineering, manufacturing, heavy machinery plant, steel industry, etc. The track laying is the most critical accessory for operating a transfer cart. The installation of industrial motorized cart tracks is different from the installation of general tracks, and the installation process is very complicated. This article will introduce the detailed steps of electric transfer cart track installation. 8 steps to get it done!
Step 1: Insulation of bolts and additional insulating pads
Based on the unique working principle of industrial flat carts, the installation requirements of flat cart tracks are different from ordinary track installation. It is required that the flat cart tracks must be insulated from each other to achieve a certain resistance value.
Given the insulation requirements of flat cart tracks, as a professional and proven electric trolley manufacturer, PERFECT introduces a method to treat the bolts with sulfur immersion insulation and add insulating elastic pads under the track pressure plate, which effectively increases the insulation resistance value between the tracks.
Step 2: Cleaning the reserved holes
First, remove the loose concrete and gravel in the reserved holes of the equipment foundation and around motorized industrial carts, then clean the debris in the reserved holes, finally use a small blower to clean the holes. If there is steel bar leakage in the reserved holes, it should be handled in time to ensure that the steel bar cannot contact the embedded bolts.
Step 3: Pre-embedded fixing bolts
- Bolt insulation: To ensure that the bolts are insulated when wet, the bolts should be soaked in sulfur. After the sulfur is melted, soak the part below the bolt thread in sulfur, take it out and dry it.
- How to install the bolts:
- Clean the oil and rust from the anchor bolts.
- After the bolts are inserted, their horizontal position and top height should be corrected and fixed.
- The amount of water used for mixing the grouting material should be less than the recommended amount of water, and the specific amount of water added should be determined according to the site requirements.
- When the grouting material is used to anchor the bolts, the following requirements should be met: the mixed grouting material should be poured into the bolt hole, and vibration and tamping are strictly prohibited during grouting. The bolts should not be adjusted after grouting. When it is difficult to directly pour the grouting, a flow channel should be used to assist the construction. If water seepage is found on the surface during the grouting process, the dry grouting material should be spread to absorb the moisture.
Step 4: Install the track of rail transfer cart
- Align the center line of the track with the center line of the rail beam, and measure the span again to ensure that it meets the requirements.
- Compress and tighten the track with a pressure plate.
- Check and adjust the track again to ensure the accuracy of the span, and at the same time ensure that the track joint gap is >2mm, the joint height difference and misalignment are <1mm; The height difference of the two tracks in the same section is <10mm; The misalignment distance of the joints of two tracks is >200mm; After it is accurate, tighten it again.
Compared with ordinary track installation, the only difference is to addition of an elastic insulating pad under each track pressure plate.
Step 5: Install the copper busbar
We all know that the copper busbar should be installed with bolts. That is to say, first weld the channel steel on the side of the track, and then connect the copper busbar and the channel steel with bolts. The connection between the copper busbars should be welded with copper welding rods.
Step 6: Test the track resistance
After the track and copper busbar are installed, the track resistance test must be carried out. Conventionally, multimeters, ohmmeters and other tools should be used for testing. However, according to the actual situation on site, if there is rust on the track surface, or there is poor contact between the bolts and the track, the bolts and the steel bars often cannot get the actual value. They cannot accurately express whether the track resistance meets the requirements. Therefore, an electric welder can be used for testing, which is intuitive and clear.
The specific method is: to connect one end of the electric welder ground wire to one track and use a welding gun to weld the other track. If only induction sparks are generated and welding cannot be performed, it means that the resistance value meets the requirements. If welding slag can be generated, it means that the current is connected and the resistance value cannot meet the requirements.
Step 7: Conceal the track and copper busbar
The concealment of the track is divided into two parts, namely the track pressure plate and the copper bar. To ensure insulation, asphalt sand is used for sealing, and we conceal the rest with concrete.
Step 8: Test run motorized transfer trolley
Put a motorized transfer trolley on the track for a test run. If there are any problems, check and solve them one by one. If there are no problems, it can be officially put into use.
Hope these methods are helpful to you. If you also have concerns, you can contact us today. We are the leading electric trolley manufacturer in China, with a 21-year history of producing and exporting, PERFECT provides riced and experienced material handling solutions, until now, our main products are AGV, RGV, rail transfer cart, steerable transfer cart, hydraulic lifting cart, rail turntable, gantry crane, overhead crane, electric hoist, winch etc. We are committed to producing the best and most efficient industrial material handling solutions. If there are any special requirements for any order, even if you don’t know whether your industrial can use our rail transfer carts, we will also be very happy to meet your requirements and help you design the entire motorized material handling project together.
