How to extend the service life of electric pallet tilters?

2025-09-03 11:58:05

The core of extending the service life of the electric tray flipping machine lies in the full cycle management of "scientific use, preventive maintenance, environmental control, and regular maintenance", which needs to cover multiple dimensions such as equipment operation, core component protection, and operating environment adaptation. Specific implementation can be carried out through the following five module systems:

Standardized operation: Reduce "human losses" from the source

Most early failures of equipment are caused by non-standard operations, which require standardized processes to avoid damage such as overload and misoperation. Specific requirements:

Strictly adhere to the load limit

Confirm the rated load of the equipment before each use and strictly prohibit overloading operation; If irregular goods need to be flipped, ensure that the center of gravity is centered to avoid excessive force on one side causing deformation of the flipping mechanism.

Avoid "emergency stop, emergency start, and overtravel" operations

Slowly adjust the speed knob during startup to avoid excessive instantaneous surge current of the motor; Before stopping or switching directions, reduce the operating speed to minimize the inertial impact of the transmission mechanism;

Relying on the device's built-in "flip angle limit" and "tray in place detection" sensors, without manually forcing overtravel, to prevent limit switch failure or mechanical structure jamming.

Compliant placement of goods

The pallet should be placed steadily at the center of the turntable to avoid uneven stress on the equipment caused by cargo displacement; If the goods have sharp edges and corners, protective pads should be installed to prevent scratches on the flip table panel or hydraulic piston rod, and to avoid potential corrosion hazards.

Strengthen the "preventive maintenance" of core components

The core components are the key to the lifespan of the equipment and require targeted maintenance to be carried out on a periodic basis

1. Power and transmission system: reduce wear and prevent jamming

Motor: Check the bearing lubrication every 3-6 months, and check the winding insulation resistance every year. If there is a temperature rise exceeding 80 ℃ or abnormal noise during operation, stop the machine immediately for troubleshooting;

Reducer: Strictly follow the instructions to change the oil regularly, clean the debris at the bottom of the oil tank before each oil change, and avoid worsening gear wear;

Chain/gear/belt: Check the tension every week, apply special lubricating oil every 2 weeks, and replace immediately if cracks, broken teeth, or aging are found.

2. Hydraulic system: leak proof and pollution proof

Hydraulic oil: Replace 46 # anti-wear hydraulic oil every 6-12 months, and clean the oil tank filter and hydraulic valve to avoid impurities blocking the oil circuit; Filter the oil every time it is replenished to prevent dust and moisture from entering;

Hydraulic cylinder and seals: Clean the surface of the piston rod after each use, check the seals monthly, and replace them immediately if there is any oil leakage to avoid insufficient system pressure or cylinder wear caused by hydraulic oil loss.

3. Structural components and connecting components: rust proof and anti loosening

Flip table, bracket and other metal structures: repair the painted areas with anti rust paint every quarter to avoid rusting in humid environments; If there is deformation or weld cracking in the structural components, the machine should be stopped immediately for welding repair to prevent stress fracture;

Bolts, nuts, and other connecting components: Use a torque wrench to tighten key parts every month to avoid loosening caused by vibration, which can lead to component misalignment and wear.

Optimizing the operating environment: reducing "environmental losses"

Adverse environments can accelerate equipment aging, and targeted improvements are needed:

Moisture-proof and dust-proof

If the equipment is used in wet/dusty workshops such as food and chemical industries, waterproof and dustproof covers should be installed on the motors and control boxes, and the surface dust of the equipment should be cleaned daily;

When idle for a long time, the equipment should be moved to a dry and ventilated place, and covered with plastic film after power off to prevent the motor winding from getting damp and the metal parts from rusting.

Anti high temperature and anti-corrosion

Avoid placing equipment near heat sources, as high temperatures can cause aging of the motor insulation layer and a decrease in hydraulic oil viscosity. If necessary, install a cooling fan;

If there is corrosive gas in the workshop, it is necessary to regularly wipe the surface of the equipment with neutral cleaning agents to prevent metal parts from being corroded, and at the same time, install anti-corrosion enclosures for electrical components.

Regular 'deep maintenance': early detection of hidden faults

Daily maintenance cannot cover all hidden issues and requires annual in-depth maintenance

Disassembly and inspection of core components

Reducer: After disassembly, check the wear of the gear teeth, clean the bearings, and check the clearance;

Motor: After disassembly, check whether there is a turn to turn short circuit in the rotor and stator windings, clean the carbon brush powder on the surface of the commutator, and replace the carbon brush with excessive wear.

Comprehensive inspection of electrical system

Use a multimeter to check if the voltage and current of the control circuit are normal, and replace aging cables and terminals;

Test the safety protection function to ensure that the device can immediately shut down after triggering, avoiding safety accidents caused by protection failure.

Precision calibration of structural components

Calibrate the flipping table surface with a spirit level. If the table surface tilts more than 0.5 °, adjust the height of the bracket to avoid deviation when the goods are flipped;

Check the accuracy of the flipping angle. If the deviation exceeds ± 2 °, adjust the position of the limit sensor or repair the flipping mechanism.

Personnel Management: Enhancing 'Maintenance Awareness'

The lifespan of equipment is directly related to the professionalism of operators and maintenance personnel, and management needs to be strengthened through training

Operator training

New employees need to receive equipment operation training before starting work, and can only operate after passing the assessment. The training content includes: load limit, operating procedures, emergency shutdown methods, and common fault identification;

Unauthorized personnel are prohibited from operating the equipment to avoid damage caused by misoperation.

Maintenance personnel training

Regularly organize maintenance personnel to study equipment manuals, familiarize themselves with the structure of each component, maintenance cycle, and lubricant model, and avoid component damage caused by improper maintenance;

Establish a 'maintenance responsibility system', clarify each person's maintenance area and responsibilities, record maintenance records, facilitate traceability and optimization of maintenance plans.

summary

Extending the service life of the electric tray flipping machine is essentially a combination of prevention and control - reducing human damage through standardized operation, reducing component wear through preventive maintenance, reducing environmental erosion through environmental optimization, and identifying hidden faults through in-depth maintenance. Long term adherence to the above measures can extend the service life of equipment by 30% -50%, while reducing downtime and improving production efficiency.