Transfer carts (AGVs) for heavy loads. A case study.

One of the most common and important processes in many of the industries we serve is the movement and transportation of heavy and specialized loads, mostly within the plant itself.

To carry out this task, they use systems such as transfer carts, carts, AGVs, AMRs, trolleys, industrial trailers, etc.

In this specific case, our client, Jaso Industrial Cranes has designed transfer carts capable of moving 25t y 35t respectively. This are equipped with our Bidirectional DC/DC converter EPC 3k5 648iHL.

The 25t transfer cart is intended for transporting heavy metal profiles, while the 35 t model will be used for moving metal scrap and metal shredding machines.

Both transfer carts are manually operated and reach a speed of 20 m/min.

The converter serves as the battery charger for the transfer cart.

The main advantage of using a bidirectional DC/DC converter is the ability to use the same industrial 400Vac inverters that are commonly used, but powered by 48V batteries.

When the 400Vac inverter is connected, the batteries automatically start charging, eliminating the need for external chargers and other accessories that would normally need to be plugged into the cart or require extra handling.

These transfer carts usually operate under extreme conditions, exposed to dirt, dust, and other residues.

The electronic boards in our converters are covered with a special protective layer to prevent corrosion and ensure an electronic lifecycle of over 30 years.

Why using bidirectional DC/DC converters in an AGVs?

This are the main benefits:

• Regenerative solution with battery usage.
• Reduced idle consumption thanks to battery energy storage.
• Space savings due to the removal of the braking resistor.
• Space savings in the warehouse and cost reduction due to the removal of the battery charger.

All isolated bidirectional DC/DC converters from epic power, including those installed in the transfer carts by Jaso Industrial Cranes, feature efficiencies of up to 98%, allowing for a reduction in component size, which is a key factor in space-constrained environments such as inside an AGV or a transfer cart.

Power flow diagram of the transfer cart with bidirectional DC/DC converter

Below is a simple diagram showing the basic configuration of the components and the energy flow.

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