Electric flat car sudden power failure is a very headache situation, not only delay the production progress, but also may bring potential safety hazards. To solve this problem, we must first figure out the cause of power failure.
Wiring is electric transfer cart power supply ‘channel’, if there is a problem, like a clogged pipe, the current can not flow properly, resulting in power outages.
Commonly, the wiring is aged or damaged. Long-term use or environmental factors can cause the outer skin of the wiring to wear out and the inner wires to be exposed, resulting in short circuits or broken circuits.
In addition, the line joints loose is also very common, the vibration of the operation will make the joints screws loose, the contact resistance increases, and when the heat is serious, it will cut off the power. In some high-temperature, high-humidity, or corrosive gas environments, the line is more likely to be damaged, pay extra attention.
The controller is the ‘brain’ of electric transfer cart, controlling the operation of the motor. If the controller fails, it may lead to power failure. For example, the internal components of the controller are aged and damaged, such as capacitors, burnt chips, etc., which will affect its normal operation.
Also, poor heat dissipation can cause problems. The controller will heat up when running. If the cooling fan fails or serious dust accumulation in the heat sink, the heat can not be dissipated, the controller may activate overheating protection and power failure.
When encountering complex operating instructions or voltage fluctuations, the controller may also crash or incorrectly act, triggering a power failure.
When the voltage of the enterprise where electric transfer cart is located is unstable or fluctuates greatly, the surge protection device will activate to cut off the power supply and protect the main board. Just like when the voltage at home is unstable, the appliance may automatically switch off.
To solve this problem, you can check the power supply system and install a voltage regulator to stabilise the voltage; you can also check the settings of the surge protection device and contact the manufacturer to adjust it if necessary.
Batteries age over time and lose capacity and performance. The internal chemicals become less responsive and unable to provide a stable charge, which can easily lead to a power failure. For example, some electric transfer carts that have been in use for many years, which used to work normally for a long period of time, and then have a shortened range and sudden power failure during operation, are likely to have an aging battery.
Judgement of battery aging, you can use professional equipment to detect the battery capacity and internal resistance, capacity significantly reduced, internal resistance increases, it means that the battery should be replaced.
Loose, corroded, or broken battery connecting wires will cause poor contact between the battery and electric transfer cart electrical system, blocking current transmission and leading to power failure. During daily inspection, pay attention to whether the connecting wire is firm, and whether there is corrosion or oxidation at the interface, and clean or replace it in time when problems are found. When installing the battery, make sure the connecting wires are tightly connected and the screws are tightened.
Over-discharging is very damaging to the battery and can cause the battery voltage to be too low, triggering the protection mechanism and leading to power failure. When using electric transfer cart, keep an eye on the power level to avoid continuing to use it even if the power level is too low. You can set a battery level alarm to remind timely charge. In addition, when not in use for a long time, you should also charge the battery regularly to prevent self-discharge, leading to over-discharge.
Motorized transfer cars run on rails, the condition of which affects their normal operation. If the track is not installed correctly, is uneven or twisted, it will vibrate violently during operation, causing electrical components to come loose and causing a power failure.
Serious wear and tear and deformation of the track can also make motorized transfer cars run erratically. What’s more, when the track is blocked by debris and the flat car is forced to pass through, it may damage the equipment and lead to a power failure.
Therefore, it is important to check and maintain the track regularly to ensure that it is firmly installed, the surface is smooth, and debris is cleared in a timely manner.
Wheels are the key components of motorized transfer cars. If the wheels are unevenly worn or the bearings are damaged, abnormal resistance and vibration will occur during operation, increasing the load on the motor.
In order to overcome the resistance, the current of the motor will increase, which may lead to overload protection and power failure. If you find abnormal wear and rattling of the wheels, check them in time and replace the worn parts and damaged bearings. Normally, pay attention to adding lubricant to the wheels and bearings to reduce wear and tear.
Motorized transfer cars have a specified load range. Overloaded cars may start at first, but after driving for a certain distance, the motor and electrical system are under too much pressure and may stop suddenly. This is just like a person who carries too much weight on his or her back and can no longer walk for a while. When using a motorized transfer car, be sure to follow the load requirements strictly to avoid overloading.
Sudden power failure during the operation of motorized transfer cars is caused by a variety of factors. In daily use, we should do a good job of checking and maintaining the equipment, and find and solve the potential problems in time, in order to ensure its stable operation and improve the production efficiency. If you can’t solve the problem of power failure, contact professional maintenance personnel.
