In modern logistics and warehousing scenarios, electric forklifts play an irreplaceable role. They efficiently transport all kinds of goods and maintain the smooth flow of materials. In the electrical structure of electric forklifts, although the DC contactor 215A/24V (small size) is small in size, it undertakes the key function of power control and is just like the “key hub” of the entire system.

Xiao Wang is a young and skilled forklift operator. The logistics center where he works is busy with business, and there are a large number of goods that need to be loaded, unloaded and transported every day. One day, Xiao Wang was driving an electric forklift to shuttle in the warehouse as usual, preparing to move a batch of pallets filled with goods to the designated shelves. When he operated the forklift to lift the goods, an accident happened. The lifting action of the forklift suddenly became extremely slow and was accompanied by a slight tremor. The motor made an abnormal buzzing sound, as if it was struggling to operate.

Xiao Wang immediately realized that the forklift had malfunctioned. With his basic understanding of the mechanical and electrical systems of the forklift, he suspected that the problem might lie with the DC contactor. He quickly drove the forklift away from the working area, parked it in a safe position, and then opened the electrical control cabinet of the forklift. Among numerous electrical components, he found the unremarkable DC contactor 215A/24V (small size).

After careful inspection, Xiao Wang found that there was some black carbon deposit on the surface of the contacts of the contactor, and some of the contacts seemed to have slight ablation marks. This might be due to the frequent control of the on-off of current for a long time. The electric sparks generated when the current passed through gradually oxidized and wore out the metal on the surface of the contacts. The carbon deposit and ablation led to an increase in the contact resistance of the contacts and a reduction in the current transmission efficiency, so that the motor couldn’t obtain enough power to normally drive the lifting mechanism of the forklift.

Xiao Wang knew very well that if this problem couldn’t be fixed in time, it would not only affect the current goods handling task but also might lead to more serious electrical failures and even endanger the safe operation of the forklift. He immediately asked the maintenance team of the logistics center for help.

The maintenance personnel quickly arrived at the scene. They conducted a more in-depth detection and analysis of the DC contactor. Using professional tools, they carefully disassembled the contactor, carefully cleaned the carbon deposit on the surface of the contacts, polished and repaired the contacts with slight ablation, and replaced the severely ablated parts with new contact components. During the maintenance process, the maintenance personnel explained to Xiao Wang, “Although this DC contactor 215A/24V (small size) is small in size, it is one of the core components in the power control of the forklift. It controls a current as high as 215A under a voltage of 24V and precisely coordinates the operation of the motor, just like traffic lights directing the passage of vehicles. In daily operation, try to avoid the forklift running continuously under high load for a long time. At the same time, regularly check the cleanliness of the electrical system to prevent dust and debris from entering the inside of the contactor, which can effectively extend its service life.”

After the meticulous repair by the maintenance personnel, the DC contactor resumed its normal working state. Xiao Wang restarted the forklift and successfully completed the goods handling task. This experience made Xiao Wang deeply realize the importance of the DC contactor 215A/24V (small size). Since then, when operating the forklift, he has paid more attention to standardized operations and regularly cooperated with the maintenance personnel to conduct comprehensive maintenance on the forklift, always paying attention to the operating status of this “key hub” to ensure that the electric forklift can play a stable and efficient role in the logistics center and provide a solid guarantee for the smooth progress of the entire logistics operation.