What should be paid attention to when using the electric transaxle in the material handling system?

What should be paid attention to when using the electric transaxle  in the material handling system?

1. Choose the right electric transaxle
1.1 Choose the right drive axle model according to the load, speed and working environment of the material handling system
When choosing a electric transaxle , the load, speed and working environment of the material handling system should be considered comprehensively. For example, for a material handling system with a large load, such as a battery forklift, its drive axle must have sufficient load-bearing capacity. For example, the ST13 drive axle has a designed load-bearing capacity of 13t and a vehicle axle shell wall thickness of 16mm, which is suitable for heavy-duty operations. At the same time, the speed ratio of the drive axle will also affect the handling speed. For example, the speed ratio of the ST13 drive axle has different options such as 3.93, 4.42, and 4.8. You can choose the appropriate speed ratio to match the handling speed according to actual needs. In addition, the working environment also affects the choice of the drive axle. For example, in a humid or dusty environment, a drive axle with better sealing performance should be selected to prevent lubricating oil contamination and damage to the machine parts.

# 2. Installation and commissioning
2.1 Ensure that the drive axle is installed correctly and the tightening torque of the fasteners meets the requirements
When installing the drive axle, you must strictly follow the installation guide provided by the manufacturer to ensure that the installation position of the drive axle is accurate. For example, the installation angle and position deviation of the drive axle should not exceed ±1° to ensure the stability of the vehicle and the efficiency of power transmission. At the same time, the tightening torque of the fasteners is also crucial. For example, the tightening torque of the half-axle bolts should be controlled within the range of 300-350N·m. Too tight or too loose will affect the service life and safety of the drive axle. During the installation process, a professional torque wrench should be used for tightening, and tightened step by step in the prescribed order to ensure uniform force on the fasteners.
2.2 Debug the steering and braking systems of the drive axle to ensure their normal operation
The steering and braking systems of the drive axle are the key to the safe operation of the material handling system. When debugging the steering system, it is necessary to check the free travel of the steering gear, which should generally be controlled between 10°-15°. Too large or too small will affect the sensitivity and accuracy of the steering. At the same time, it is necessary to ensure that the steering system is not stuck and the steering should be smooth and unobstructed. For the braking system, it is necessary to check the clearance of the brakes, such as the clearance between the brake shoe and the brake drum of the drum brake should be kept within the range of 0.2-0.3mm to ensure the braking effect. In addition, it is necessary to perform performance tests on the braking system, such as emergency braking at a specified speed, checking the braking distance and braking stability of the vehicle, and ensuring that the braking system can work reliably.

# 3. Lubrication and maintenance
3.1 Regularly check the amount and quality of lubricating oil in the drive axle and replace the lubricating oil in time
The lubricating oil of the drive axle is one of the key factors to ensure its normal operation. Regularly checking the amount and quality of lubricating oil can effectively prevent drive axle failures caused by insufficient or deteriorated lubricating oil. For example, during the use of the drive axle of a battery forklift, the lubricating oil will gradually deteriorate due to high temperature and mechanical wear and lose its lubricating effect. It is generally recommended to check the amount and quality of lubricating oil every 500 hours of work or every quarter. When the lubricating oil turns black, has an odor or impurities appear, it should be replaced in time. When replacing the lubricating oil, you should choose the lubricating oil that matches the drive axle model. For example, the ST13 drive axle recommends using SAE 85W-90 gear oil to ensure the lubrication effect. At the same time, when replacing the lubricating oil, the inside of the drive axle should be thoroughly cleaned to prevent the old oil residue from affecting the performance of the new oil.
3.2 Clean the drive axle regularly to prevent dust and impurities from entering
The cleaning of the drive axle is equally important. Dust and impurities entering the inside of the drive axle will accelerate the wear of the parts and reduce the service life of the drive axle. Cleaning the drive axle regularly can effectively prevent the accumulation of dust and impurities. For example, a material handling system used in a dusty environment should clean the drive axle once a week. When cleaning, use a clean cloth or brush to remove dust and oil from the surface of the drive axle, and pay special attention to cleaning the vents and sealing parts of the drive axle to maintain its good ventilation and sealing performance. In addition, during the cleaning process, the seals of the drive axle should be checked for damage. If damaged, they should be replaced in time to prevent dust and impurities from entering the inside of the drive axle from the damaged part.

# 4. Operation monitoring
4.1 Monitor the operating temperature of the drive axle to prevent overheating
Operation temperature is one of the key indicators for the normal operation of the drive axle. Excessive temperature can cause the lubricating oil to deteriorate, the wear of the parts to increase, and even cause failures. For example, when the operating temperature of the drive axle exceeds 90℃, the viscosity of the lubricating oil will drop significantly, the lubrication effect will deteriorate, and the wear of the gears and bearings will accelerate. Therefore, the operating temperature of the drive axle must be monitored in real time to ensure that it is within the normal range. Under normal circumstances, the normal operating temperature of the drive axle should be between 60℃-80℃. The temperature change of the drive axle can be monitored in real time by installing a temperature sensor. When the temperature exceeds the set threshold, take cooling measures in time, such as increasing the speed of the cooling fan or checking the cooling system for faults.
4.2 Monitor the operating sound of the drive axle and detect abnormalities in time
Operation sound is an important basis for judging whether the drive axle is working properly. The normal operating sound of the drive axle should be smooth and uniform, without obvious abnormal sounds. If there is an abnormal sound, such as a sharp whistle, knocking or friction sound, there may be a problem with the internal parts of the drive axle. For example, poor gear meshing will produce a whistling sound, bearing damage will produce a knocking sound, and poor lubrication will produce a friction sound. By regularly monitoring the running sound of the drive axle, potential fault hazards can be discovered in time. It is recommended to conduct a sound check once a day after the material handling system is started and during operation. If an abnormal sound is found, the machine should be stopped immediately for inspection, the cause should be found and repaired to avoid further expansion of the fault and ensure the safe operation of the material handling system.

# 5. Troubleshooting
5.1 Timely troubleshooting of drive axle faults, such as abnormal noise, oil leakage, etc.
During the operation of the material handling system, the failure of the drive axle will seriously affect the normal operation and safety of the system. Timely detection and troubleshooting are the key to ensuring the efficient operation of the system.
Abnormal noise fault: Abnormal noise is one of the common faults of the drive axle, which may be caused by poor gear meshing, bearing wear or insufficient lubrication. For example, when the gear meshing clearance is too large, a periodic whistling sound will be generated; bearing wear may produce continuous friction sound. Once an abnormal sound is found, the machine should be stopped immediately for inspection. First, check the amount and quality of lubricating oil to ensure good lubrication; then check the wear of gears and bearings, and adjust or replace them if necessary. According to statistics, timely handling of abnormal noise faults can extend the service life of the drive axle by more than 30%.
Oil leakage fault: Oil leakage not only causes the loss of lubricating oil, but also may pollute materials and working environment. The cause of oil leakage may be aging, damage or improper installation of seals. For example, damage to the half-shaft oil seal is one of the common oil leakage points. Regularly check the sealing performance of the seals and replace them in time when damage is found, which can effectively prevent oil leakage. At the same time, when installing seals, they should be operated in strict accordance with technical requirements to ensure that they are installed in place. By regular inspection and timely replacement of seals, the incidence of oil leakage faults can be reduced by more than 50%.
5.2 Regularly check the parts of the drive axle and replace damaged parts in time
Regular inspection of the parts of the drive axle is an important measure to prevent failures and extend the service life of the drive axle.
Inspection cycle: It is recommended to conduct a comprehensive inspection of the drive axle every 1000 hours of work or every six months. The inspection content includes the wear and tightening of key parts such as gears, bearings, and bolts. For example, the degree of gear wear can be judged by measuring the tooth thickness. When the tooth thickness wear exceeds 10% of the original tooth thickness, the gear should be replaced.
Replacement of parts: For severely worn parts, they should be replaced in time. For example, the wear of the bearing will lead to unstable operation and increased noise. When the radial clearance of the bearing exceeds the specified value, the bearing must be replaced. At the same time, when replacing parts, the same model or equivalent quality as the original should be selected to ensure the performance and reliability of the drive axle. Regular replacement of worn parts can reduce the failure rate of the drive axle by more than 40%.

# 6. Safety precautions
6.1 Ensure that the operator of the material handling system is familiar with the operation and maintenance knowledge of the drive axle
The operator’s mastery of the operation and maintenance knowledge of the drive axle directly affects the safe operation of the material handling system and the service life of the drive axle. According to relevant surveys, drive axle failures caused by improper operation account for about 30% of the total failures. Therefore, it is necessary to ensure that the operator is familiar with the following:
Operation specifications: The operator should strictly follow the operating manual of the material handling system and the drive axle to avoid illegal operations such as overloading and overspeeding. For example, when using a battery forklift, the operator should reasonably choose the driving speed according to the weight of the goods and the handling distance to avoid overloading the drive axle due to excessive speed.
Daily inspection: The operator should conduct daily inspections on the drive axle, including checking the amount and quality of lubricating oil, the tightening of fasteners, the sealing performance of seals, etc. Timely detection and handling of potential problems can effectively prevent the occurrence of failures.
Maintenance: The operator should understand the maintenance cycle and content of the drive axle, such as regular replacement of lubricating oil, cleaning of the drive axle, and inspection of parts wear. And perform maintenance according to the prescribed time and requirements to extend the service life of the drive axle.
6.2 During material handling, pay attention to avoid collision between the drive axle and obstacles
During material handling, the collision between the drive axle and obstacles will not only cause damage to the drive axle, but may also cause safety accidents. Therefore, the operator should pay attention to the following points:
Observe the road conditions: The operator should always observe the road conditions during driving, and pay attention to obstacles in front and around, such as cargo stacking, other vehicles, personnel, etc. Slow down or avoid in advance to avoid collisions.
Reasonable route planning: Before handling materials, the driving route should be planned reasonably, and try to avoid narrow, crowded or obstructed areas. For example, when handling goods in a warehouse, the best driving route should be selected according to the storage location and channel conditions of the goods to reduce the risk of collision.
Control the speed: During driving, the speed should be reasonably controlled according to the road conditions and the requirements of the handling task. Avoid being unable to react and avoid obstacles in time due to excessive speed. For example, when driving in narrow passages or crowded areas, the speed should be reduced to ensure safety.

# 7. Summary
When using a drive axle in a material handling system, multiple factors need to be considered comprehensively to ensure the safe and efficient operation of the system and the service life of the drive axle. Through the detailed analysis of the above chapters, the following key points can be summarized:
Choose a suitable drive axle: According to the load, speed and working environment of the material handling system, choose a suitable model of drive axle, such as the ST13 drive axle, which has a design load capacity of 13t and a variety of speed ratio options to meet different needs.
Installation and commissioning: Strictly follow the manufacturer’s installation guide to ensure that the drive axle is installed correctly and the tightening torque of the fasteners meets the requirements. At the same time, debug the steering and braking systems to make them work properly.
Lubrication and maintenance: Regularly check the amount and quality of lubricating oil, and replace the lubricating oil in time, such as checking every 500 working hours or every quarter; regularly clean the drive axle to prevent dust and impurities from entering, such as cleaning once a week in a dusty environment.
Operation monitoring: Real-time monitoring of the operating temperature of the drive axle to ensure that it is within the normal range of 60℃-80℃; by monitoring the operating sound, timely detect abnormalities, such as howling, knocking or friction sounds, and immediately stop for inspection.
Troubleshooting: Timely eliminate drive axle faults, such as abnormal noise and oil leakage, regularly check parts, and replace damaged parts in time, such as conducting a comprehensive inspection every 1000 working hours or every six months.
Safety precautions: Ensure that the operator is familiar with the operation and maintenance knowledge of the drive axle, and avoid illegal operations such as overloading and speeding; during material handling, pay attention to avoid collisions between the drive axle and obstacles, plan routes reasonably, and control vehicle speed.
In summary, through the above precautions and measures, the operating efficiency and safety of the material handling system can be effectively improved, the service life of the drive axle can be extended, and the failure rate and maintenance costs can be reduced.