KPT Cable Reel Powered Rail Transfer Cart for Workshop

• Most Cost-Effective Power Supply Solution: Direct 380V cable power eliminates the need for conductor rail installation costs and battery replacement expenses, making it the lowest initial investment and operating cost option among rail transfer cart power supply methods.
• Extremely Simple Structure for Easy Maintenance: Unlike conductor rail carts (requiring current collectors and rails) and battery carts (requiring battery management systems), the KPT only has three main components – cable, electrical cabinet, and drive unit – resulting in the fewest potential failure points.
• No Usage Time Limitations: Unlike KPX battery carts that require 6-8 hours of charging, the KPT can operate continuously for 24 hours, making it ideal for continuous three-shift production scenarios.
• Low Rail Installation Requirements: Unlike KPD low-voltage rail carts (which require insulated rails and segmented power supply), the KPT has no special requirements for the rails, allowing for rapid deployment in both new and existing workshops.
• Low Overall Height: The motor and gearbox are horizontally mounted inside the chassis, keeping the overall height to only 450~1200mm (depending on capacity), suitable for low-clearance factory buildings.
• Rich Expandable Features: Optional add-ons include a hydraulic lift platform, tipping device, V-type support, rotating table, remote control system, explosion-proof electrical control, and variable frequency speed control.

The working principle of the KPT cable-reel powered rail-type electric flat car is based on direct cable supply:

A 380V AC cable is laid on the floor along the centerline of the rails. One end of the cable is connected to the workshop's power distribution cabinet (equipped with leakage protection and short-circuit protection), while the other end is dragged along the floor as the cart moves. The cable length is typically 1.2 to 1.5 times the travel distance to provide sufficient slack for dragging.

The cart is equipped with a cable entry device that brings the 380V power supply into the cart's electrical control cabinet via cable connectors. Components inside the cabinet, such as circuit breakers, contactors, and thermal overload relays, distribute and protect the power supply. An isolation transformer (380V/36V) provides a safe voltage for the control system.

The operator uses a wired control pendant or wireless remote control to switch the contactors, driving the three-phase asynchronous motor (0.8~15kW depending on the model). The motor speed is reduced by a cycloidal gearbox and transmitted through open gears to drive the wheels along the rails.

For travel distances exceeding 15m or higher travel speeds, it is recommended to add a cable drag chain (engineering plastic chain). The cable is fixed within the chain links and moves with the cart, preventing direct wear from dragging on the floor. The bending radius of the drag chain should be 6 to 8 times the cable's outer diameter.

The KPT cable-reel powered rail-type electric flat car consists of the following main structural components:

• Chassis (Load Platform): Fabricated from Q235B steel plates into a box-type structure, with main girders reinforced using I-Beam or H-Beam sections. Capacity is designed in grades from 2t to 150t. The 150t chassis uses Q345B low-alloy high-strength steel.
• Wheel Block: Cast steel wheels (ZG310-570) with hardened treads (HB320-380). Wheel diameter ranges from Φ270 to Φ600, with 4 or 8 wheels (8 wheels for the 150t model). Bearings are double-row spherical roller bearings.
• Drive Unit: YE3 series high-efficiency motor + cycloidal gearbox (or hardened tooth flank gear reducer for the 150t model). The motor has IP54 protection and Insulation Class F.
• Cable Entry Device: Comprises cable connectors, a cable fixing frame, and an anti-pullout mechanism. The cable enters from the bottom or side of the cart, protected by a cable sheath (wear-resistant rubber) and cable clamps to prevent fracture at the connection point due to frequent bending. A drag chain guide channel is optional.
• Electrical Control Cabinet: Stainless steel 304 enclosure with IP54 protection. Built-in circuit breaker, contactor, thermal overload relay, isolation transformer (380V/36V), and switching power supply. The control circuit operates at 36V safety voltage and is equipped with emergency stop, overload, short-circuit, and phase loss protection. Optional PLC (Siemens S7-200 SMART) and VFD (Siemens V20/G120) available.
• Cable drag chain (optional): Engineering plastic chain, sized according to cable outer diameter and quantity. Bending radius of the drag chain: 150–300mm, travel speed ≤30m/min. Chain links are detachable for easy cable inspection and replacement.

• Cross-bay transfer in foundry workshops: At a precision foundry, a KPT-16t cable-reel flat car was installed between the core-making line and the cleaning line, covering a distance of just 12m with a cable drag chain power supply. Previously, forklifts shuttled sand cores back and forth, achieving an average of 80 transfers per day. After switching to the KPT, throughput rose to 120 transfers per day, and the core damage rate dropped from 8% to below 2%.
• Die forging transport in forging workshops: At a heavy industry manufacturer's forging workshop, a KPT-40t flat car handles short-distance transport of die forgings from the heating furnace to the forging press (distance ≤18m). With an ambient temperature of 45–55°C, the trailing cable was specified as a high-temperature resistant type (-40°C to +105°C) and has been running continuously for 2 years without replacement.
• Workpiece transfer between welding stations: For short-distance movement of large structural components between welding stations, a KPT-25t flat car shuttles along the welding line over distances of 8–15m. Paired with manual remote control operation, the car's overall height of just 600mm allows it to pass beneath welding platforms.
• Quenching part transport in heat treatment workshops: A KPT-10t flat car fitted with a heat-resistant protective cover transports workpieces between the quenching tank and the heating furnace. The trailing cable design avoids the insulation aging issues that conductor rails suffer from in high-temperature, high-humidity environments.
• Heavy material delivery on assembly lines: A KPT-20t flat car delivers core components such as engines and gearboxes along the assembly line over distances of 6–10m, with point-to-point precise positioning. Delivery efficiency is 40% higher than an AGV solution, at only one-quarter of the investment cost.

• Load capacity: Select based on the maximum single-trip transport weight, with a recommended 20%–30% margin. For long-distance (>15m) or high-frequency (>20 trips/hour) applications, it is recommended to step up one size.
• Travel distance: The KPT trailing cable solution is best suited for short-distance transport of ≤20m. Beyond 20m, consider the KPJ cable reel or KPC conductor rail solutions. For distances >10m, a cable drag chain is strongly recommended.
• Table dimensions: Customized length and width based on workpiece geometry. Non-standard sizes are available when standard table dimensions do not meet requirements.
• Environmental conditions: For high-temperature environments (>50°C), specify high-temperature resistant cable (-40°C to +105°C) and high-temperature resistant motors (Class F/H insulation). For explosion-proof environments, specify explosion-proof electrical control (Ex db eb IIB T4 Gb). For outdoor use, add a rain cover.
• Function expansion: Hydraulic lifting (150–300mm stroke), Variable Frequency Speed Control, Wireless remote control, PLC automation, and other options available on request.

• Pre-Sales Consultation: Free Technical Solution, model selection advice, and layout drawings.
• Order Processing: Foundation condition drawings provided within 3 days of contract signing; full machine test run and Acceptance before shipment.
• Installation & Commissioning: On-Site Guidance available from our technical staff (cost quoted separately).
• Training Support: Operator Training (1–2 days) covering operating procedures, routine inspections, and common fault troubleshooting.
• After-Sales Service: 1-year warranty on the complete machine (excluding Wear Parts); on-site response within 48 hours domestically.
• Spare Parts Supply: Long-term supply of Cable drag chains, cables, Gearbox / Reducers, Wheel Blocks, Bearings, electrical components, and more.

Q: What's the difference between the KPT cable-powered flat car and the KPC conductor rail car?

A: The KPT uses a 380V cable directly dragged for power supply, eliminating the need for conductor rails and trenches, resulting in the lowest initial investment. It's ideal for short-distance applications with a travel distance ≤20m. The KPC requires installing conductor rails and a trench, which involves a higher initial investment but allows for unlimited travel distance (up to 100m+). The choice depends on your travel distance and budget.

Q: How long does the KPT cable last?

A: Cable lifespan depends on dragging frequency, environmental conditions, and whether a Cable drag chain is used. When dragged directly on the ground without a chain, standard rubber-sheathed cables typically need replacement every 6–12 months. With a Cable drag chain, cable life can be extended to 2–3 years. We recommend using special oil-resistant, abrasion-resistant, and Temperature Resistance rubber-sheathed cables.

Q: Will the cable on the KPT car get crushed during operation?

A: The cable is laid on the ground between the two Crane Rails, while the car's wheels run on the rails, so they never come into contact with the cable. A protective conduit or sheath under the car deck shields the cable from falling objects. In the Cable drag chain configuration, the cable is fully enclosed within the chain links for even greater safety.

Q: What is the maximum travel distance for the KPT car?

A: The standard cable drag configuration is recommended for a maximum of 20m. For distances beyond 20m, we suggest considering the KPJ Cable Reel or KPC conductor rail options. If using a Cable drag chain system, a practical distance is 15–20m. Excessive dragging distances accelerate cable wear and lead to excessive Voltage drop.

Q: Can the KPT cable-powered car be automated?

A: Yes. The KPT car can be equipped with optional PLCs (Siemens S7-200 SMART/S7-1200), Frequency Inverter / VFDs (Siemens V20/G120), and positioning sensors (Laser Distance Measurement/Encoder), which integrate with a central dispatching system for automatic calling and travel. The cable power supply is naturally suited for automation (no charging required), achieving Positioning Accuracy of ±10mm.

Q: What national standards does the electric flat car comply with?

A: The Design & Manufacturing of the KPT series rail-type Electric Flat Car strictly adheres to the JB/T 6127-2010 industry standard for electric flat cars. The electrical system complies with GB 5226.1-2019 requirements for electrical safety of machinery, and the control system passes a dielectric withstand Test (1500V/1min). Before shipment, each machine undergoes a three-stage Acceptance process: full-load test run, Dynamic Load Test, and Static load test, ensuring safety and reliability. Factory inspection reports and Type Test reports are available upon request.

Q: Can the KPT car be used outdoors?

A: Yes, it can be used outdoors on hard, level surfaces, but with some considerations: use weather-resistant cable (UV-stabilized, Temperature Resistance range -40℃~+105℃), add a Rain Cover to the electrical cabinet, and ensure the rail foundation is designed to prevent water accumulation. Use in muddy or heavily waterlogged outdoor areas is not recommended.