KPD Series Low-Voltage Rail Flat Car for Industrial Transport
Low-Voltage Rail Electric Flat Car
Model: KPD series; Rated Load Capacity: 6-160 tons; Power supply: low-voltage rail (36V); Travel Speed: 20-30 m/min.
The KPD series low-voltage rail electric flat car operates on a 36V low-voltage rail power supply system. Safe voltage is delivered to the car via the conductor rail, then stepped up by an onboard transformer to drive the motor. Since no trailing cable is required, the KPD flat car is safe, reliable, resistant to impact and heat, and does not obstruct cross-traffic during operation. It is also easy to equip with remote control and automation, offering greater flexibility in plant layout.
The KPD series includes two sub-models: KPD (single-phase) and KPDS (three-phase). The KPD uses a single-phase capacitor motor with a maximum load capacity of 50 tons, while the KPDS employs a three-phase YZ metallurgical duty motor rated up to 160 tons. A KPDZ (DC) series is also available, featuring a DC traction motor for smoother starting and higher overload capacity.
Product Introduction
The KPD series is a 36V low-voltage rail-powered electric flat car. It draws power from the conductor rail to start and run. With no trailing cable, it delivers safe and reliable operation, withstands impact and heat, and allows unobstructed cross-traffic — while being readily adaptable to remote control and automated systems for greater plant layout flexibility.
Product Images
Product Features
- Safe low-voltage power supply: The 36V rail voltage is inherently safe, eliminating electric shock hazards for both operators and maintenance personnel.
- Impact and heat resistant: With no exposed cables and rails embedded in the track bed, the car withstands falling heavy objects and high-temperature exposure — ideal for demanding environments like steel mills and foundries.
- No obstruction to cross-traffic: Rail-powered operation eliminates cable dragging, allowing other vehicles to move freely across the workshop floor.
- Automation-ready: The low-voltage rail supply is naturally suited for remote control and automated operation, and can be easily integrated into a centralized workshop control system.
- Adaptable to harsh environments: With insulated rails, the system performs reliably in high-temperature, high-dust, and humid conditions, with low maintenance requirements.
- Multiple model options: KPD (single-phase ≤50t), KPDS (three-phase ≤160t), and KPDZ (DC ≤160t) cover a wide range of application needs.
Operating Principle
KPD (single-phase): A floor-mounted step-down transformer in the control cabinet reduces three-phase 380V AC to single-phase 36V AC, which is fed to the car through the conductor rail. An onboard step-up transformer then raises the voltage back to single-phase 380V AC to power the single-phase capacitor motor. Because the starting current drawn through the rail is extremely high (up to 1000A), a significant voltage drop occurs at the far end of the rail, making it difficult for the single-phase capacitor motor to start. This limits the KPD to a maximum load capacity of 50 tons. The KPD also places high demands on the rail system: since the rails carry current, they must be properly insulated, copper compensating conductors are required at intervals to offset voltage drop over longer distances, and additional transformers may be needed for extended travel lengths.
KPDS (three-phase): A floor-mounted step-down transformer reduces three-phase 380V AC to three-phase 36V AC, which is delivered via the conductor rail and stepped back up to 380V AC by the onboard transformer to power YZ metallurgical duty motors. The balanced three-phase supply results in lower starting current, enabling higher load capacities (up to 160t) and longer travel distances.
KPDZ (DC): The KPDZ retains the advantages of the KPD while overcoming its starting difficulties and limited travel range. An onboard rectifier converts the single-phase (or three-phase) 36V AC from the rail into 36V DC to drive a DC traction motor. Compared to AC motors, DC motors offer superior resistance to burnout, higher starting torque, and greater overload capacity. The KPDZ continues to operate reliably even under undervoltage conditions caused by aging rail insulation.
Structural Composition
The KPD series low-voltage rail electric flat car consists of the following core components:
Frame: Fabricated from Q235B (≈S235JR) steel plate by welding, followed by annealing to relieve internal stress. The main girder uses a box-section design with load-bearing capacity optimized through FEA.
Rail power supply system: Includes the floor-mounted step-down transformer (380V to 36V), rail insulation components, copper compensating conductors, and conductor rail pickup assemblies. Rail insulation is critical — the rails must be reliably insulated from the track bed to prevent leakage and short circuits.
Onboard electrical system: The KPD/KPDS is equipped with a step-up transformer (36V to 380V); the KPDZ uses a rectifier unit (AC 36V to DC 36V). The control box houses a circuit breaker, contactor, and thermal overload relay, providing overload and short-circuit protection.
Drive system: The KPD uses a single-phase capacitor motor (2.2-7.5kW); the KPDS is powered by YZ series three-phase asynchronous motors (2.2-7.5kW×2); the KPDZ employs a DC traction motor.
Wheel assembly: Cast steel wheels with induction-hardened tread surfaces (HRC45-50), fitted with spherical roller bearings that automatically compensate for installation misalignment.
Technical Parameters
| Model | KPD | KPD6 | KPD10 | KPD16 | KPD25 | KPD40 | KPD63 | KPD100 | — |
|---|---|---|---|---|---|---|---|---|---|
| Model | KPDS | KPDS6 | KPDS10 | KPDS16 | KPDS25 | KPDS40 | KPDS63 | KPDS100 | KPDS160 |
| Rated Load Capacity(t) | 6 | 10 | 16 | 25 | 40 | 63 | 100 | 160 | |
| Table Dimensions (mm) | LengthL | 3600 | 3600 | 4000 | 4500 | 5000 | 5600 | 6300 | 8000 |
| WidthB | 2000 | 2000 | 2200 | 2200 | 2500 | 2500 | 2800 | 2800 | |
| HeightH | 550 | 550 | 580 | 650 | 700 | 850 | 900 | 1150 | |
| Start Button(m/min) | 30 | 30 | 30 | 30 | 25 | 25 | 20 | 20 | |
| Bottom Clearance(mm) | 50 | 50 | 50 | 60 | 60 | 60 | 60 | 60 | |
| Wheel Diameter(mm) | 400 | 400 | 400 | 500 | 500 | 600 | 600 | 600 | |
| Gauge (Inside Rail Distance)C(mm) | 1435(Customizable 762-2000mm) | ||||||||
| WheelbaseA(mm) | 2000 | 2000 | 2200 | 2500 | 2800 | 3200 | 3600 | 4500 | |
| motor power (Kw) | KPD | 2.2 | 3.5 | 5 | 7.5 | — | |||
| KPDS | 2.2 | 3.7 | 5.5 | 7.5 | 7.5 | 7.5×2 | |||
| Power Supply Mode | KPD | Single Phase 380V36V 380V PDG-10S | Single Phase 380V36V 380V PDG-20S | — | |||||
| KPDS | Three Phase 380V36V380V PSG-10S | Three Phase 380V36V380V PSG-20S | |||||||
| Reference Weight(t) | 2.5 | 2.7 | 3.5 | 4.6 | 6.0 | 8.6 | 10.6 | 22.5 | |
| Recommended Rail | P24 | P38 | P43 | P50 | |||||
Why Choose Kelude Heavy Industry
- 17 Years of Industry Expertise: Kelude Heavy Industry specializes in the R&D and manufacturing of electric flat cars. Our KPD series low-voltage rail cars have served numerous metallurgical, foundry, and processing enterprises both domestically and internationally.
- Comprehensive Model Coverage: Three power supply options are available — KPD single-phase, KPDS three-phase, and KPDZ DC — covering the full load capacity range of 6 to 160 tons to meet diverse operating conditions.
- Custom Engineering Capabilities: Table dimensions, rail gauge, load capacity, and automation interfaces (PLC/remote control/autonomous operation) can be tailored to your specific site conditions.
- Complete After-Sales Service: A 24-hour national service hotline, with on-site installation guidance, operator training, and regular inspections.
Service & Support
Henan Kelude Heavy Industry Co., Ltd. provides full life-cycle services for KPD series low-voltage rail electric flat cars: pre-sales solution design (model and power supply recommendation based on your operating conditions), in-sales installation & commissioning (technical personnel on-site to guide rail insulation and trial operation), and post-sales warranty (12-month full machine warranty). Spare parts are available for long-term supply, and annual maintenance agreements can be arranged.
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Frequently Asked Questions (FAQ)
Q: Does the rail of the KPD series low-voltage flat car require insulation treatment?
A: Yes. The KPD series uses the rail as a live conductor, so the rail must be reliably insulated from the track bed, typically using insulated base plates or insulating mastic. Rail joints also need copper bonding straps to minimize resistance voltage drop. Installation requirements are more stringent than for standard electric flat car rails. We can provide standard rail installation drawings.
Q: What are the differences between the KPD, KPDS, and KPDZ models?
A: KPD uses single-phase power supply (≤50t) with a single-phase capacitor motor — simple construction but higher starting current. KPDS uses three-phase power supply (≤160t) with a YZ three-phase motor for balanced and smooth starting. KPDZ uses DC power supply (≤160t), rectifying 36V AC to DC to drive a DC motor, offering high starting torque and strong overload capacity, and remains reliable even under undervoltage conditions.
Q: What travel distance can the KPD series low-voltage flat car achieve?
A: Under standard configuration, the travel distance is approximately 100–200 meters. Beyond that, additional copper bonding straps are required to compensate for rail voltage drop, and additional transformers may be needed for longer distances. The KPDZ DC option offers the best tolerance to voltage drop and achieves the longest travel distance under equivalent conditions.
Q: Can the KPD series electric flat car be operated by remote control?
A: Yes. The low-voltage rail power supply of the KPD series is inherently well-suited for remote control and automation. Wireless remote control (100–200 meters) is available as an option, and PLC integration enables automatic positioning and synchronized operations. The control system complies with JB/T 6127-2010 and GB 5226.1-2019 standards.
Q: What advantages does the KPD series low-voltage flat car offer over other power supply options?
A: The core advantages of KPD are safety (36V low voltage) and no trailing cable (immune to impact and heat damage, and does not obstruct cross traffic). Compared to KPC which requires trench construction, KPT with limited travel distance, and KPX which requires charging downtime, KPD offers distinct advantages in harsh environments such as metallurgy and foundries. The trade-off is that the rail requires insulation treatment and more demanding installation.
