What are the Installation Requirements of the Rail of Electric Transfer Cart
Proper rail installation is key to the stable and safe operation of electric transfer carts. Below are the core requirements:
1. Foundation Requirements
Load - Bearing Capacity: The foundation (minimum C30 concrete) must bear the combined weight of rail, cart, and goods. Reinforcement may be needed for heavy loads.
Flatness & Levelness: Foundation surface deviation ≤3 - 5mm/m; correct unevenness before installation.
Stability: No cracks or subsidence. Outdoor/humid areas require waterproof and anti - corrosion treatments.
2. Rail Material & Specifications
Material: Use high - quality steel (e.g., Q235B) meeting standards. Special environments need anti - high - temperature/corrosion coated rails.
Dimensional Accuracy: Cross - sections comply with specs; straightness deviation ≤1mm/m. Avoid bent or cracked rails.
Surface Quality: Smooth, free from burrs/rust. Remove rust via sandblasting/grinding before installation.
3. Rail Alignment & Positioning
Center Line Accuracy: Align with the cart's designed path; deviation ≤±3mm (use total stations/laser tools).
Parallelism (Double Rails): Distance deviation between rails ≤±2mm at multiple points to prevent skewing.
Levelness: Rail top surface deviation ≤1mm/m; cumulative deviation over total length ≤10mm.
4. Rail Fixing & Connection
Fastening: Use expansion bolts (embedded ≥10× diameter depth), embedded parts, or rail clips for firm fixing.
Section Connections: End gaps 2 - 5mm (for thermal expansion); height difference ≤0.5mm, lateral deviation ≤1mm. Secure with fishplates.
Anti - Loosening: Equip fasteners with lock washers, spring washers, or thread - locking adhesives.
5. Safety & Auxiliary Requirements
Anti - Derailment: Install guide wheels/guard rails at curves, switches, or ends.
Drainage: Outdoor/humid areas need drainage to prevent water accumulation.
Clearance: ≥500mm between rails and obstacles (walls, columns, etc.).
Marking: Clearly mark center lines, start/end points, and load limits.
6. Post - Installation Inspection & Testing
Static Inspection: Check position, levelness, parallelism, and fastener tightness with professional tools.
Dynamic Testing: Run the cart under no - load and rated load; ensure smooth operation without abnormal noise/vibration.
Load - Bearing Test (Heavy - Duty): Test with 125% rated load for 1 - 2 hours; check for deformation or loosening before formal use.
Following these requirements ensures a stable, safe rail system for efficient material handling.
Special customized installation requirements for different scenarios
Low temperature/severe cold environment (such as outdoor and cold storage in the north)
Track material selection: Q355ND low-temperature toughness steel is preferred to avoid brittle cracking at low temperatures;
Basic treatment: Anti freezing agent (grade ≥ C30+F150 anti freezing grade) needs to be added to the concrete foundation to prevent the track from bulging due to winter frost heave;
Gap reservation: The gap between track joints should be 1-2mm larger than that in normal temperature environment (low-temperature shrinkage will reduce the gap and avoid joint top dead deformation).
High temperature environment (such as metallurgical and casting workshops)
Track protection: Surface sprayed with high-temperature resistant ceramic coating (capable of withstanding over 300 ℃) to prevent deformation of the track caused by dripping of high-temperature materials;
Basic insulation: Add 50mm thick aluminum silicate insulation board under the track to prevent high temperature from being transmitted to the foundation and causing concrete cracking;
Expansion treatment: For long-distance tracks (over 20 meters), one expansion joint with a width of 5-8mm should be installed every 10 meters, filled with high-temperature resistant elastic rubber strips.
High dust/high oil pollution scenarios (such as mechanical processing and auto repair workshops)
Track cleaning: During installation, reserve a "track blowing interface" synchronously, and connect one compressed air nozzle every 5 meters to facilitate daily blowing of dust and oil stains;
Fastener protection: Install a dust cover (made of oil resistant rubber) on the bolt head to prevent oil stains from penetrating the threads and preventing disassembly in the later stage.
