Rail Transfer Trolley
Industrial Heavy Load Electric Rail transfer trolley
In the process of industrial logistics automation upgrading, Rail Transfer Carts and Trackless Transfer Carts/AGVs are two mainstream solutions.
Electric Rail Transfer Cart Series are rail-guided transfer trolleys that can operate on S-shaped or curved rails, as well as on combined straight and circular arc rails, and vertical-horizontal intersecting rails, enabling full automation. This series of electric transfer trolleys features a simple structure, safety, flexibility, easy maintenance, and is suitable for heavy loads, high-frequency use, long service life, explosion-proof, high-temperature resistance, low noise, safety, and environmental protection. It is widely used in industries such as heavy industry, machinery manufacturing, petroleum, metallurgy, mining, chemical engineering, shipbuilding, coal, electromechanical, aerospace equipment, and military industry.
Electric Rail Transfer Carts can be divided into KPX battery rail transfer carts, KPD low-voltage rail transfer carts, RGV automated rail transfer carts, KPJ Cable Drum rail transfer carts, KPC sliding contact line rail trolleys, KPT trailing cable rail trolleys, etc.
Diagram of Rail Transfer Vehicle Operation Demonstration
Demonstration video of rail transfer vehicle operatio
KPX battery rail transfer cart
The KPX battery rail transfer cart is powered by lead-acid batteries or lithium batteries, equipped with an intelligent charger. The batteries supply power to the traction motor, which drives the car to operate. The DC motor or low-voltage AC motor powered by the batteries has the advantages of large starting torque and strong overload resistance.
Compared with other models of rail transfer carts, it has greater safety and maneuverability, can travel on curves and turnouts, has no restriction on operating distance, has no insulation requirements for rails, and is convenient for construction with low costs.
KPD rail electric transfer cart
The KPD rail electric transfer cart is a low-voltage rail powered electric handling cart. Its working principle is as follows: the 380V power supply (three-phase or single-phase) is reduced to a safe voltage of 36V through a ground-controlled step-down system, which is then fed to the conductive rails (which also serve as the running tracks for the cart). The low-voltage electricity is transmitted via the cart's conductive device to the step-up transformer on the cart, which boosts the voltage back to 380V to drive a three-phase or single-phase capacitor motor, propelling the transfer cart.
KPD rail transfer cart offer advantages such as safety (resistant to high temperatures, impacts), no interference with cross-transportation, easy automation, the ability to travel on curved and circular tracks, and unlimited operating distance by appropriately increasing the number of step-down transformers.
Application scope: steel, heavy industry, aerospace, coal, water conservancy, and other industries.
RGV automated rail transfer cart
RGV automated rail transfer cart are widely used in automated production workshops and lines, with multifunctional, highly intelligent automation and other customized devices. RGV automated rail cars can be divided into two types: assembly type RGV and transportation type RGV. Mainly used for material transportation, workshop assembly, etc. There are shuttle type automated rail cars and longitudinal and transverse moving automated rail cars.
The child mother type (Ferry Carts ) automated rail transfer cart can effectively transfer objects on a limited layout site. It can operate on multiple rails, with a shuttle and a span spanning to meet the needs of multiple rails, multiple stations, and automation.
The Vertical-Horizontal Moving automated rail transfer cart can operate on the cross rail, achieve rail identification and positioning, and switch rail operation trajectories. According to requirements, various handling modes such as mechanical arms and cranes can be customized on the transfer cart platform, as well as various automation functions and programs. It is widely used in special industries such as metallurgy, casting, chemical, nuclear power, and automotive manufacturing, and is an efficient handling equipment in modern chemical plants and automated production workshops.
KPC/KPT rail transfer cart
The power supply method of KPC sliding contact transfer cart is to open a trench on the side of the rail, install a safety sliding contact line in the trench, and lay a single-sided hinged cover plate on the trench fixed to the ground. During the operation of the electric transfer cart, the cover plate is lifted by installing a flipping device in the trench, and there is a cable connected to the safety sliding contact line collector inside the flipping device. The electric transfer cart automatically returns to the ground through the rear cover plate, ensuring the smooth passage of trackless transfer cart. The KPC sliding contact electric transfer cart is not limited by the running distance.
Compared to the KPX trolley, it is not restricted by usage time. Compared to the KPD trolley, it has lower requirements for track laying. Compared to the KPJ trolley, it has a lower cost.
The KPT rail transfer trolley is suitable for occasions with short operating distances (≤20m), high usage frequency, and low overall vehicle height. For scenarios with short operating distances and slow speeds, a drag chain can be used to reduce cable wear.
Rail Transfer Trolley Specification
| KPX电池轨道平车技术参数表Technical Parameters Table Of KPX Battery Transfer Cart | |||||||||||||
| 额定载重Rated Load Capacity（t） | 5 | 10 | 15 | 20 | 30 | 40 | 50 | 60 | 80 | 100 | 150 | 200 | |
| 台面尺寸 Table Size(mm) | 长Length | 2000 | 2400 | 3000 | 3000 | 4000 | 4500 | 5000 | 5000 | 6000 | 6000 | 7000 | 8000 |
| 宽Width | 1300 | 1500 | 2000 | 2000 | 2200 | 2200 | 2500 | 2500 | 2500 | 2500 | 3000 | 3000 | |
| 高Height | 450 | 500 | 550 | 550 | 600 | 600 | 700 | 700 | 800 | 800 | 900 | 900 | |
| 离地间隙Ground Clearance（mm） | ≥50 | ||||||||||||
| 轴距Wheelbase（mm） | 1300 | 1600 | 2000 | 2000 | 2700 | 3000 | 3300 | 3300 | 4000 | 4000 | 4800 | 5500 | |
| 轨内侧距Rail Inner Distance（mm） | 900 | 1100 | 1435 | 1435 | 1435 | 1435 | 1650 | 1650 | 1650 | 1650 | 2000 | 2000 | |
| 操作方式Operation Method | 无线遥控+线控手柄Remote Control & Hand Operate Pendant | ||||||||||||
| 运动方式Move Way | 直行，转弯（定制），纵横交叉移动（定制） Forward/backwards, Turning (Customized), Vertical-Horizontal Crisscross Movement (Customized) |
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| 行走速度Running Speed（m/min） | 25 | 20 | |||||||||||
| 电机类型Motor Type | 低压交流电机/直流无刷电机Low-voltage alternating current (AC) motor / brushless direct current (DC) motor | ||||||||||||
| 刹车方式Brake Mode | 电磁刹车Electromagnetic Brake | ||||||||||||
| 防护措施Protective Measures | 声光报警+急停按钮+极限保护+激光避障（选配）+防撞触边（选配）Audible and visual alarm lamp+ Emergency stop button+Limit switch+Laser obstacle avoidance sensor(Optional)+Anti-collision contact edge(Optional) | ||||||||||||
| 车轮数量Wheel Quantity | 4 | 8 | |||||||||||
| 车轮材质Wheel Material | ZG55 | ||||||||||||
| 驱动轮经 Drive Wheel Diameter（mm） | Ф300 | Ф300 | Ф350 | Ф350 | Ф400 | Ф400 | Ф500 | Ф500 | Ф600 | Ф600重Heavy Duty Wheel | Ф700重 Heavy Duty Wheel |
Ф600重Heavy Duty Wheel | |
| 推荐轨道型号 Recommended Rail Type | P15 | P18 | P24 | P24 | P38 | P38 | P43 | P43 | QU70 | QU70 | QU100 | QU100 | |
| 电池容量Battery Capacity（kW·h） | 4.8 | 7.2 | 8.6 | 8.6 | 10.5 | 14.4 | 15.8 | 18.7 | 21.6 | 28.8 | 36 | 57.6 | |
| 电池类型Battery Type | 铅酸电池Lead-Acid Battery | ||||||||||||
| 续航时长Battery Endurance | 5h（根据需求定制）Customized As Needed | ||||||||||||
| 充电时间Battery Charging Time | ≤7h | ||||||||||||
| 充电器供电Battery Charger | AC220V/AC380V | ||||||||||||
| 工作环境Working Environment | 温度：-10℃～40℃；湿度：20%～80%，无凝露(定制高温、防爆环境)Temperature: -10°c～40°c; Humidity: 20%～80%, No Condensation (Customized for high-temperature and explosion-proof environments) | ||||||||||||
| 车体颜色Vehicle Body Color | 黄色/蓝色/根据要求定制 Customized | ||||||||||||
| 其它功能Other Functions | 电量显示、过压、欠压、过流保护Battery Power Display,Over Voltage, Under Voltage, Over Current Protection etc | ||||||||||||
| RGV自动化 Versione Automatica – RGV | 搭配自动定位系统、信号接收系统、可编程系统实现RGV自动化搬运功能。可定制子母车（摆渡车）纵横移动车、弧形轨道车等RGV小车 Combined With An Automatic Positioning System, Signal Reception System, And Programmable System, The Rgv Realizes Automated Handling Functions. Customizable Rgv Carts Such As Mother-Child Carts (Ferry Carts), Vertical-Horizontal Moving Carts, And Curved Track Carts Can Be Provided. | ||||||||||||
| 注：1) 其它轨距、台面尺寸、载重吨位可根据用户需求定制； 2) 该型号轨道车可根据需求定制子母车、弧形轨道车、纵横移动车等满足使用需求的特殊车辆； 3) 该型号轨道车可接收呼叫盒、上位机指令实现自动化搬运； 4) 电池类型和续航时长可根据客户需求定制； 5）产品会不断改进升级，表内参数可能存在变动。 Notes: 1)Other gauges, table sizes, and load tonnages can be customized according to user requirements. 2)This model of rail trolleys can be customized with special vehicles such as mother-child cars, curved track carts, vertical-horizontal moving carts, etc., to meet specific usage needs. 3)This model of rail trolleys can receive instructions from call boxes and host computers to achieve automated handling. 4) Battery type and operating time (battery endurance) can be customized to meet customer needs. 5）The product is subject to continuous improvement and upgrades; specifications in the table may change without prior notice. |
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Electric Rail Transfer Cart Advantages
✅ Core Advantages
✔ High load capacity (up to 500T+, suitable for ultra-heavy transport)
✔ Stable operation (travels along fixed rails, less prone to deviation)
✔ Lower cost (simple structure, no complex navigation system)
✔ Suitable for long-distance linear transportation (such as cross-plant transfer between workshops)
❌ Limitations
✖ Fixed path with poor flexibility (cannot adapt to production line adjustments)
✖ Complex installation (requires rail laying, high ground construction cost)
✖ Limited expandability (new routes require re-laying rails)
Applications of Rail Transfer Trolley
Production and Assembly Lines
Rail transfer trolleys are ideal for transporting large and heavy components along production lines. They streamline material flow in manufacturing processes, ensuring efficient operation of assembly lines.
Storage and Logistics Centers
In storage and logistics centers, rail transfer trolleys are used for the orderly movement of large quantities of materials. They are particularly effective for transporting heavy and bulky loads within or between warehouses.Their speeds of up to 60 meters per minute enable quick transportation of high volumes of materials.
Steel and Metal Processing Industries
Rail transfer trolleys are widely used in steel mills and metal processing facilities for moving large metal plates, coils, and other heavy materials. These industries require high safety standards during material handling.
Energy and Power Generation Facilities
They can be powered by various sources including spring drums, bus-bars, cable carriers, batteries, or diesel. These carts are designed to meet different needs and ensure the continuity of energy supply.
Mining and Heavy Industry
Equipped with hydraulic and pneumatic actuators and AC/DC electric motors, rail transfer trolleys perform well even in harsh environmental conditions. Their specially designed sizes accommodate narrow tunnels or large open areas.
Shipbuilding and Maritime Industry
In shipbuilding, rail transfer trolleys handle the transport of large ship parts to assembly areas. They ensure the safe and precise movement of these large components.
Automotive Industry
In the automotive sector, rail transfer trolley play a significant role in moving large vehicle parts along production lines. These carts are manufactured in sizes tailored to different vehicle models and feature bumpers to prevent damage to loads.
Choosing Rail Transfer Cart
Rail-type – suitable for heavy-duty, fixed-route, and low-cost needs
Transporting extremely heavy goods (>50T, such as steel coils, large mechanical equipment)
Transport routes are fixed for a long time without frequent adjustments
Limited budget, expecting low equipment cost and simple maintenance
In heavy industry: rail-type still dominates (due to the demand for ultra-heavy loads)
Intelligent manufacturing & logistics: Automated RGV is the mainstream, and flexibility and intelligence are the trends
Hybrid solution: some enterprises adopt the "rail + AGV" combination, which takes both stability and flexibility into account
Precautions for Using Rail Transfer Trolley
The battery can be removed, the maintenance of the battery is convenient when charging just unplugging the electric car can make a variety of repair charger to the battery pulse repair effective input to the battery, and not by the electric transfer cart controller to repair the pulse absorption.
If in the process of overhaul: dismantling difficult phenomenon, the body of the car in many places appear local deformation, tray plane damage, lifting and unloading too difficult, below the fixed bolt removal space is narrow, too much, part of the card phenomenon is more serious.
Vehicle use, pay attention to the material shall not pile too high, material stacking firm, not loose, not load operation, equipment staff should focus on operating the vehicle, pay attention to the direction of travel in front of the situation, and observe the operation of other equipment around, to ensure that the operation does not collide with other equipment, operation, equipment operators shall not do things that are not related to work. electric transfer carts are a connection hook in front of and behind the cart so that they can pull other transfer carts or be pulled when necessary.
The track is laid in order to lay the insulation layer to avoid the leakage of the track sliding contact line, and the temporary surface of the insulation layer is covered with a layer of asphalt as a buffer layer, and then the track is installed. When installing the track, attention should be paid to the use of spot welding technology to strengthen the connection point of the track on the one hand and to extend the service life of the track on the other hand.
The reinforcement of the members should be accurate, the reinforcement surface should be flat and smooth, and the ratio of sulphur cement mortar should meet the requirements.
In the construction of the track foundation, attention should be paid to the accuracy of the vertical position of the holes of the pre-buried parts, and keep the holes clean and free of impurities.
