What should be noted in the daily maintenance of the power system for electric pallet tilters?

2025-09-03 11:58:10

The power system of the electric tray flipping machine is the core of its stable operation, mainly including key components such as the motor, reducer, transmission mechanism, hydraulic system, and electrical control system. Daily maintenance should revolve around "preventing failures, extending lifespan, and ensuring safety", and develop targeted measures based on the characteristics of different components. Specific precautions can be classified according to system modules as follows:

Core power source: Daily maintenance of the motor

The motor is the starting point of power output, and maintenance focuses on "preventing overload, overheating, and insulation aging". Specific operations:

Regularly check the operating status

Observe the appearance of the motor before each start-up to confirm that there is no damage to the casing, loose/oxidized wiring terminals, or worn cables;

During operation, use your hands or a thermometer to measure the surface temperature of the motor. If any abnormal overheating or noise occurs, immediately stop the machine for troubleshooting.

Lubrication and Cleaning

According to the motor manual, check the lubrication condition of the bearings every 3-6 months: if it is an oil containing bearing, it is necessary to confirm that the oil level is within the oil gauge line and the oil quality is not turbid or blackened; If it is a ball bearing, regularly replenish high-temperature lubricating grease to avoid dry friction causing the bearing to get stuck;

Clean the dust and oil stains on the motor cooling holes and fan blades with compressed air every week to prevent poor heat dissipation from causing motor burnout.

Insulation and overload protection inspection

Use a multimeter to check the insulation resistance of the motor winding every month. The resistance value should be ≥ 0.5M Ω. If the resistance value is too low, it may be due to the winding being damp or the insulation layer being damaged, and it needs to be dried or repaired;

Confirm that the parameters of the motor overload protector match the rated current of the motor to avoid protection failure or accidental triggering caused by improper parameters.

Power transmission components: maintenance of reducers and transmission mechanisms

The reducer and transmission mechanism are responsible for transmitting the motor power to the flipping actuator, and the maintenance focus is on "preventing wear, loosening, and abnormal noise":

1. Maintenance of reducer

Oil level and quality inspection: Observe the reducer oil gauge weekly, and the oil level should be between the "highest" and "lowest" marks. If it is insufficient, replenish the same type of gear oil; Replace the gear oil every 6 months. If the oil quality turns black or has metal debris in advance, it should be replaced immediately and the internal gear wear should be checked;

Sealing and abnormal noise investigation: Check the sealing covers of the input and output ends of the reducer every month. If there is oil leakage, replace the seals; If you hear "meshing noise" or "metal impact sound" inside the reducer during operation, it may be due to gear wear or bearing damage, and you need to stop the machine for disassembly and inspection.

2. Maintenance of transmission mechanism

Chain drive:

Check the tension of the chain every week: Press the middle of the chain with your hand, and the sag should not exceed 20mm. If it is too loose, it is easy to jump teeth, and if it is too tight, it is easy to aggravate wear; The tension can be adjusted by adjusting the position of the sprocket or the tension wheel;

Apply chain specific lubricating oil every 2 weeks, clean the oil and debris on the chain before application, and avoid mixing lubricating oil with impurities to prevent wear from worsening;

Check the opening pin and snap spring at the chain joint every month to ensure they are intact. If they come off, replace them immediately to prevent chain breakage.

Gear transmission:

Monthly inspection of gear meshing surface: If there is tooth wear, pitting or tooth breakage, the machine needs to be stopped for maintenance; The meshing surface should be kept clean and regularly lubricated with a brush dipped in gear oil.

Belt drive:

Check the tension of the belt every week: Press the middle of the belt, with a suitable sag of about 10-15mm. If it is too loose, it is easy to slip, and if it is too tight, it is easy to break the belt or damage the bearings;

Check the surface of the belt every month: if there are cracks, aging, or edge wear, replace the belt with the same model in a timely manner; The surface of the pulley needs to be cleaned to avoid slipping caused by oil stains.

Maintenance of hydraulic auxiliary system

Some electric tray flipping machines are equipped with hydraulic systems to assist in flipping, and the core maintenance components are hydraulic pumps, hydraulic cylinders, hydraulic oil, and seals:

Hydraulic oil inspection: Observe the oil level in the hydraulic oil tank every week and replenish the same type of hydraulic oil if it is insufficient; Replace the hydraulic oil every 6-12 months and clean the oil tank filter to avoid impurities blocking the hydraulic valve;

Leakage and pressure investigation: Check the hydraulic pipeline joints and the sealing of the hydraulic cylinder piston rod every month. If there is oil leakage, replace the seals; Confirm whether the system pressure is within the rated range through a pressure gauge during operation. Abnormal pressure may be caused by hydraulic pump wear or overflow valve failure;

Hydraulic cylinder maintenance: Clean the surface of the piston rod after each use to avoid dust and oil stains from adhering and causing seal wear; If there are scratches or deformations on the piston rod, it should be repaired in a timely manner to prevent hydraulic oil leakage or hydraulic cylinder jamming.

Maintenance of electrical control system

The electrical system is the "brain" of the power system, directly affecting equipment start stop, speed regulation, and safety protection. The maintenance focus is on "preventing short circuits, poor contacts, and component aging":

Control box and wiring inspection:

Open the control box every week, clean the internal dust with compressed air, check if the wiring terminals are loose, and if there are oxidation marks, use sandpaper to polish and re tighten them;

Check the contacts of contactors and relays every month: if the contacts are burned, replace the contacts or the entire component to prevent poor contact and motor phase loss operation.

Inspection of sensors and safety components:

Electric tray flipping machines are usually equipped with "limit sensors", "emergency stop buttons", and "overload protection switches". Before starting each day, they need to be tested:

Press the emergency stop button to immediately shut down the device and reset it before it can start normally;

Manually triggering the limit sensor, the device needs to stop the corresponding action to avoid overtravel damage;

Wipe the sensor probe with alcohol every month to remove dust and oil stains, ensuring accurate signal detection.

Cable and plug maintenance:

Check the outer skin of the power and control cables of the equipment daily. If there is any damage or aging, wrap them with insulating tape or replace the cables;

If it is a mobile device, avoid crushing or pulling the cables, and keep the plugs and sockets dry and clean to prevent water ingress and short circuits.

General maintenance principles and safety precautions

Establish a maintenance ledger: record the time, components, operation content, and equipment operation status of each maintenance, in order to trace the cause of faults and develop subsequent maintenance plans;

Shutdown maintenance: All maintenance operations must be carried out when the equipment is powered off or stopped. If testing operation is required, it is necessary to ensure that there are no personnel or obstacles around, and that the emergency stop button can be reached with one hand;

Spare parts and tool preparation: Reserve commonly used vulnerable parts and use matching tools for maintenance;

Professional maintenance: In case of complex faults such as motor burnout, gearbox gear fracture, hydraulic system pressure loss control, etc., it is necessary to have qualified professionals repair to avoid secondary damage or safety risks caused by self disassembly.

Through the above targeted maintenance, the probability of failure of the power system of the electric tray flipping machine can be effectively reduced, the service life of the equipment can be extended, and the safety during operation can be guaranteed, avoiding equipment damage or personnel injury caused by power component failure.