Henan Aifite Intelligent Equipment Co., LTD.
Overload Standards for Industrial Electric Transfer Flatbed Carts
2025-12-02
Analysis of Load Capacity and Overload of Industrial Electric Transfer Flatbed Carts
The safe overload range for industrial electric transfer flatbed carts is generally 1.2 to 1.5 times the rated load, i.e., 120% to 150%. This is a consensus in industry design standards and safety regulations.
I. Basic Overload Capacity
Standard Safety Factor: The safety factor of electric flatbed carts is generally no less than 1.2 in design, and high-quality products can reach 1.5.
Rail-mounted electric flatbed carts: Can withstand approximately 1.5 times the rated load.
Trackless electric flatbed carts: Due to the lack of track support, the overload capacity is slightly lower, approximately 1.2~1.3 times.
II. Safety Protection Mechanisms (Overload)
Overload Degree | Protection Measures
90% Rated Load | Warning Prompt (Audio and Visual Alarm)
100%~120% | Automatic Speed Reduction (e.g., from 1 m/s to 0.5 m/s)
≥120% | System Lock down, Cannot Start
Electrical Protection | Automatic Power Cut-off When Current Exceeds 150% of Rated Value
III. Overload Capacity of Different Types of Electric Flatbed Carts
1️⃣ Rail-mounted Electric Flatbed Cart
Bearing Advantages: The track distributes the weight, resulting in stronger load-bearing capacity.
Typical Rated Load: 5 tons ~ 350 tons
Short-term Impact Load: Can reach 1/3 of the rated load. 15% (e.g., a 75-ton flatcar can withstand an impact of 112.5 tons)
Applicable Scenarios: Heavy equipment handling, large work-piece transfer
2️⃣ Trackless Electric Flatcar
Rated Load Capacity: Generally several tons to 50 tons, custom-made up to 100 tons
Design Features: Limited tire load capacity; overloading can easily lead to tire deformation
Applicable Scenarios: Flexible transfer within the factory, where fixed tracks are not required
IV. Risks of Overloading
Structural Damage: Long-term overloading leads to frame deformation and weld cracking
Motor Burnout: Overload operation causes overheating, shortening motor lifespan
Battery Loss: High-current discharge accelerates battery aging
Brake Failure: Overloading increases braking distance, raising safety risks
Service Life: Significantly shortens the normal service life of the equipment
V. Usage Recommendations
Prohibit Long-Term Overloading: Even if the equipment has overload capacity, it should be used strictly according to the rated load.
Short-Term Overload Limits: If temporary overloading is necessary, it should not exceed the rated load. 120%, and for single, short-distance use only.
Even load distribution: Avoid concentrated loads and ensure even weight distribution.
Regular inspection: Especially after overloading, the structure and electrical system should be inspected.
Summary: The safe overload range for industrial electric transfer flatbed carts is 120%~150% of the rated load, but long-term overloading is strictly prohibited in actual use. The safety factor designed for the equipment is to cope with emergencies and short-term impacts, not for daily overloading operations. Long-term overloading will seriously affect the equipment's lifespan and bring safety hazards. If it is necessary to move goods close to the rated load, it is recommended to choose a model with a higher rated load to ensure safety and long-term stable operation of the equipment.
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