1.5x Speed Chain: The Golden Choice for Intelligent Conveying in Light Industry

In Dongguan, an electronic parts factory workshop, a 1.5 times the speed of the chain is seemingly slow but very rhythmic rhythm. When the workpiece board carrying semi-finished circuit boards arrived at the inspection station, the pneumatic blocker fell noiselessly, the workpiece board instantly static -Dynamic freezing in 0.3 secondsThe pallets in the other zones are still flowing at a constant speed. This wisdom of "separation of motion" is the unique value that 1.5x chain brings to light industrial conveying.

I. Principle of growth rate: 1.5 times the mechanics of the code

The mystery of the 1.5x chain stems from itsDouble Diameter Roller SystemThe precision fit of the

  • ​Roller-roller diameter ratio: The small diameter roller (d) in contact with the guideway provides the base velocity (v₀) and the large diameter roller (D) in contact with the work plate generates the additional velocity (v₁), according to the motion superposition equation:
    ​V = v₀ + (D/d) × v₀ = v₀ × (1 + D/d)​
    When D/d=0.5 (e.g. d=20mm, D=30mm), the theoretical growth rate ratio reaches 1.5 times
  • ​Friction loss compensation: the actual kinetic energy consumption of 15% due to sliding friction, the final speed of the plate is about 1.3-1.4 times the speed of the chain.

​Exclusive validation data: A packaging factory in Suzhou measured that when the chain speed is set to 8m/min, the actual speed of the workpiece is 11.2m/min-...Hidden Growth Rate 40%The efficiency increase is 25% compared with the normal drum line.

II. Structural analysis: the delicate balance of lightweight design

Unlike the complex structure of the 2.5x chain, the 1.5x chain uses aThree-in-one Minimalist Architecture::

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1. **Bearing module**  
   - Engineering Plastic Roller (Nylon + 30% Glass Fibre)  
   - Compressive strength 120MPa, weight 67% lighter than steel wheels  
2. **Transmission core**  
   - Carburised steel rollers (surface hardness HRC58-62)  
   - Diameter tolerance strictly controlled within ±0.03mm  
3. **Connection system**  
   - Pin type chain link (disassembly time is 80% shorter than riveted type) [3](@ref)  


This design allows the 1.5x speed chain to maintain thestructural rigiditywhile at the same time achievingSelf-weight of only 2.4kg per metre(3.8kg for 2.5x speed chain), especially suitable for ceiling suspended wire bodies.




Third, the performance advantage: the golden partner of the light industrial scene


A comparative test at a power plant in Huizhou reveals the core differences:






​norm​
1.5x speed chain
2.5x speed chain
Conventional drum line






​noise level​
58dB
63dB
71dB




​Retrofit time​
2 hours
8 hours
24 hours +




​power consumption​
3.2kW/100m
5.1kW/100m
4.0kW/100m




​maintenance cost​
¥86/m/year
¥142/m/year
¥203/m/year






​Irreplaceable value dimensions::


    

  • ​Advantages of dynamic and static conversion: Blocker response time ≤ 0.5 seconds to realise theMillimetre precision stops(±1.5mm)
    • 

  • ​Spatial adaptability: Minimum turning radius 0.6m (1.2m for 2.5x speed chain), suitable for old plant renovation
    • 

  • ​Economic breakthrough: Acquisition cost of 65% at only 2.5x speed chain, ROE cycle reduced to 14 months
    • 





IV. The Light Industrial Scene: A Performance Revolution in Three Major Areas


1. The silent revolution in food packaging lines


A chocolate factory in Hangzhou after the adoption of 1.5 times the speed chain:


    

  • ​Noise Reduction Effectiveness: Reduction of workshop noise from 72dB to 55dB, in accordance with EU EN 352 standards
    • 

  • ​Hygiene upgrade: Food-grade nylon rollers FDA-approved, microbial residues down 90%
    • 

  • ​temperature adaptation: Remains flexible in a -5°C refrigerated environment (rubber rollers will harden)
    • 



2. Flexibility paradigm for light industrial electronics assembly


Smart transformation of Shenzhen power adapter factory:


    

  • ​Dynamic speed control: 4-12m/min stepless speed change via frequency converter
    • 

  • ​Quick changeoverReplacement of POM engineering plastic rollers takes only 45 minutes and is compatible with different PCB sizes.
    • 

  • ​Anti-static design: Surface resistance controlled in the range of 10⁶-10⁹Ω, ESD damage rate reduced to 0.01%
    • 



3. Clean guarding of medical device assembly


A breakthrough in a syringe factory in Jiangsu:


    

  • ​Dust-free operation: Enclosed rail design for particulate emissions <100 particles/m³ (ISO Class 5 standard)
    • 

  • ​Lubrication Revolution: Lubricated with medical white oil and certified biocompatible by USP Class VI.
    • 

  • ​sterilisation toleranceWithstands steam sterilisation at 132°C, with a life decay rate of <15%.
    • 





V. Selection and Configuration: Avoiding Pitfalls for 90% Users


​Fatal Misconceptions Corrected::


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- **Misconceptions**: Direct application of the motor power of the 2.5x speed chain  
- **Truth**: The 1.5x chain tension formula needs to be corrected to:  
  **T ≥ [m x g x (μ + 0.03) + m x a] x 1.8**  
  (μ is taken as 0.18-0.22; 0.03 is the friction coefficient of the speed increasing mechanism) [1](@ref)  


​The Golden Rule of Allocation::


    

  1. 

    ​Roller Material Selection Matrix​
    

    


    
take
Preferred Material
life span
contraindication (medicine)

    
    


    
Food packaging
POM+PTFE coating
5-7 years
Banning of plain nylon

    

    
electronics assembly
Anti-static nylon
4-6 years
Metal rollers are prohibited

    

    
medical equipment
Medical grade polyurethane
3-5 years
Prohibition of silicone-containing materials

    
    

    

    2. 

  2. 

    ​Guide to avoiding the pitfalls of drive systems​
    

      

    • Motor power redundancy taken as 1.3 times (1.8 times for non-standard 2.5 times speed chain)
      • 

    • The frequency converter must support S-curve acceleration and deceleration (to avoid tipping of the workpiece)
      • 

    • Hysteresis tensioner recommended (tension fluctuation <5%)
      • 

    

    3. 





VI. Maintenance Evolution: The Secret to a 20,000 Hour Lifespan


​Turning traditional maintenance programmes on their head::


    

  • ​Lubrication Revolution::
    
Conventional oil →Lithium thickener + molybdenum disulphideSynthetic grease (viscosity 220 cSt)
    
Maintenance intervals extended from 500 to 2000 hours
    • 

  • ​Wear monitoring::
    
Monthly testing of chain link elongation by laser rangefinder (warning value: 1.2%)
    
Roller dents > 0.3mm trigger preventive replacement
    • 



​Future Evolutionary Directions::


    

  • ​Intelligent sensing of links: Embedded MEMS sensors (size 2 x 2mm) in the pin, real-time monitoring of stress peaks
    • 

  • ​Self-repairing coatings: 3μm diamond-like coating (DLC) deposited on the surface of the rollers, friction coefficient reduced to 0.05
    • 

  • ​Digital twin maintenance: Predicts faults through current fluctuation mapping, increasing repair response time by 40%
    • 





Self-questioning: six questions about 1.5x multiplier chains


​Q1: Can I replace the 2.5x chain in wet environments?​




Absolute Advantage! Engineered plastic rollers last 3 times longer than steel wheels in humidity > 80% environments and will not rust.




​Q2: How can the maximum load break the 30kg/m limit?​




Three Major Techniques:


    

  1. Conversion to double-row chain structure (150% wider carrying surface)
    2. 

  2. Guide rails with auxiliary support wheels
    3. 

  3. Upgraded C-type steel roller (compressive strength increased 200%)
    4. 





​Q3: Why are silicone-based lubricants banned?​




Silicone oil can penetrate engineering plastics leading to dissolution and a company lost $2.7 million as a result.




​Q4: Does cost compression sacrifice reliability?​




Wisdom compression method:


    

  • Replacement of stainless steel with aluminium alloy for guide rails (45% cost reduction, only 15% strength reduction)
    • 

  • Nylon rollers for non-load-bearing sections (weight-reducing 40%)
    • 

  • Linear section eliminates lateral guide rails (rational layout can reduce costs by 30%)
    • 





​Q5: When must I upgrade to a higher multiplier chain?​




When both are satisfied:


    

  • Conveying speed requirement >15m/min
    • 

  • Load >50kg/m
    • 

  • Stopping accuracy requirement <0.5mm
    • 





​Q6: Will it be eliminated in the future?​




On the contrary! The modular design makes itThe best carrier for flexible production linesIn 2026, the global market share of light industry will exceed 38%.








Three 1.5x chains have been running continuously for 19,000 hours in a class 100,000 clean room in a medical device factory in Zhejiang. Their roller surfaces have a subtle pearly sheen - a self-lubricating crystal layer formed by polyurethane molecules in countless frictions. ThisIntelligent adaptation derived from material instinctsThe 1.5x speed chain is the ultimate code for the longevity of the 1.5x speed chain in the light industry: to find a delicate balance between efficiency and cost with just the right growth rate ratio. When China's manufacturing shifts from scale expansion to lean production, this kind of "golden ratio" technology will become the breaking edge for SMEs.

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