What are the types of power systems for pallet tilters?

2025-09-03 11:58:15

The power system of a tray flipping machine is the core component that determines its flipping efficiency, load capacity, applicable scenarios, and operational safety. Different types of power have significant differences in driving principles, performance characteristics, and applicable scenarios. Starting from the classification of power sources, this article provides a detailed introduction to the structure, advantages, limitations, and typical applications of various power systems, helping users choose the appropriate solution based on their actual needs

Electric power system

The electric power system takes the motor as the core driving source, and converts electrical energy into mechanical torque through transmission mechanisms such as reducers, chains/gears/belts to achieve the flipping action of the tray. It is currently the most widely used type in industrial scenarios.

1. Core components

Drive motor: divided into DC motor and AC motor; Some high-end models will use servo motors, which can accurately control the flipping speed and angle.

Transmission mechanism: A common combination of "motor+reducer+sprocket/gear" is used. The reducer is used to reduce speed and increase torque, and the transmission components are mostly made of high-strength steel to ensure stable load transmission.

Control system: Combined with PLC or relay control, it can achieve functions such as "one key flip", "emergency stop", "automatic power-off in place", etc. Some models support linkage with the MES system of the production line.

2. Advantages

Environmentally friendly and clean: No risk of oil leakage, suitable for industries such as food, medicine, electronics, etc. that require high environmental cleanliness.

Strong controllability: The flipping speed and angle can be accurately adjusted, and the start stop impact is small, reducing the risk of cargo tipping.

Low energy consumption and easy maintenance: Compared to hydraulic systems, the energy consumption of motors is only 60% -80%. Daily maintenance only requires regular checks of motor wiring and lubrication of transmission components, without the need for frequent oil changes.

3. Limitations

Limited load limit: The load of a single motor driven flipping machine is usually within 5 tons, and if it exceeds 10 tons, multiple motors need to be linked, resulting in higher costs.

Sensitive to power supply stability: Voltage fluctuations may cause abnormal motor start stop, requiring the use of a voltage regulator or backup power supply.

4. Typical applications

Food/pharmaceutical industry: Tray flipping in cleanrooms.

E-commerce/Logistics: Turning or flipping of pallets for light goods.

Hydraulic power system

The hydraulic power system uses hydraulic oil as the transmission medium, generates pressure through hydraulic pumps, drives hydraulic cylinders or motors to operate, and then drives the pallet flipping mechanism to move. Its core advantage is "high torque, high load", suitable for flipping heavy goods.

1. Core components

Power unit: including hydraulic pump, motor, oil tank, and relief valve.

Execution mechanism: mostly double acting hydraulic cylinders or hydraulic motors, some models use a combination of "hydraulic cylinder+gear rack" to improve flipping stability.

Control system: Hydraulic valve group, some high-end models are equipped with electro-hydraulic proportional valves to achieve precise speed control.

2. Advantages

Extremely strong load capacity: Single cylinder drive can achieve a load flip of 10-50 tons, and some customized models can exceed 100 tons.

Good impact resistance: The "buffering characteristic" of hydraulic oil can absorb the inertial impact during the flipping process, making it suitable for heavy and irregular goods and reducing the risk of deformation.

Adapt to harsh environments: Hydraulic components have strong sealing and can work in dusty and humid environments.

3. Limitations

There is a risk of oil leakage: the aging of hydraulic pipe joints and sealing rings may cause oil leakage, pollute the environment, and require regular replacement of seals.

High maintenance costs: Regular replacement of hydraulic oil and cleaning of filter elements are required, and the technical threshold for repairing components such as hydraulic pumps and valve groups is high, resulting in higher costs than motors.

Slow flipping speed: The response speed of hydraulic transmission is lower than that of the motor, and the single flipping time is usually 10-30 seconds.

4. Typical applications

Heavy industry: steel mills, machinery factories, ports.

Building materials industry: flipping pallets for heavy-duty building materials such as cement and tiles.

Pneumatic power system

The pneumatic power system uses compressed air as the transmission medium, and converts pneumatic energy into mechanical energy through cylinders or pneumatic motors to drive the flipping mechanism. Its core features are "low cost, simple structure, and no oil pollution", suitable for light load and low-frequency flipping scenarios.

1. Core components

Air source unit: relying on the factory's compressed air pipeline network, it needs to be equipped with filters, pressure reducing valves, and oil mist devices, known as "pneumatic triple components".

Execution mechanism: mostly single/double acting cylinders, some small models use pneumatic motors.

Control system: solenoid valve, one-way throttle valve, structure much simpler than electric/hydraulic system.

2. Advantages

Extremely low cost: The price of pneumatic components is only 30% -50% of that of motors/hydraulic components of the same specifications, and there is no need for complex control systems.

Clean and pollution-free: driven by compressed air, with no risk of oil/electrical sparks, suitable for "low-cost clean scenes" in the food and pharmaceutical industries.

Extremely easy to maintain: no motor windings, hydraulic oil or other vulnerable parts, only need to check whether the air pipe joint leaks in daily life, and troubleshooting is simple.

3. Limitations

Weak load capacity: Single cylinder drive load is usually within 1 ton, with a maximum of no more than 3 tons.

Dependent on gas source: A compressed air system must be installed. If the factory does not have a gas source, additional air compressors need to be purchased to increase initial investment.

Poor stability: Fluctuations in air pressure can lead to unstable flipping speed, and the cylinder has a large "rigid impact", which can easily cause damage to lightweight and fragile items.

4. Typical applications

Light industry: small food factories, electronics factories.

Temporary/Simple Scenario: A light load flipping workstation temporarily added to the workshop.

Core recommendations for power system selection

Prioritize direction based on "load":

Light load: choose electric or pneumatic;

Medium to heavy load: choose electric or hydraulic;

Overloading: Hydraulic is mandatory.

Refine based on the "industry environment":

Food/Medicine/Electronics: Resolutely exclude hydraulic and choose electric or pneumatic;

Mining/Metallurgy/Port: Excluding pneumatic, choose hydraulic or electric.

Balancing efficiency and cost:

High frequency flipping: choose electric;

Low frequency flipping: optional pneumatic or hydraulic, reducing initial investment.

Through the above comparison, the most suitable pallet flipping power system can be accurately matched based on actual load, environment, and efficiency requirements, while ensuring long-term stable operation of the equipment.