Wuxi Ring Speed Chain: Conveying Engine for Smart Factory

​Innovative Practices of Wuxi Enterprises::

• ​Material innovation: Travostone adopts a combination of engineering plastic rollers (light load) and carbon steel rollers (heavy load) to control the rate of loss of speed increase within 5% when carrying a 2000kg cylinder block on the automotive parts production line;
• ​Precision controlAluminium alloy guide rail with surface hardening treatment, straightness error ≤ 0.3mm/m, to avoid resonance offset during high-speed operation;
• ​Energy consumption optimisationThe powerless free section adopts 2° inclination design, the energy consumption of return journey is zero, and the total power consumption of the system is 62% lower than that of the traditional conveying line.

​Local case validationAfter adopting triple-speed chain, a new energy battery factory in Wuxi has achieved a daily capacity of 3,500 pieces in a ring space of 18 x 8 metres.Increased output per unit area 55%--Confirms the synergistic effect of spatial reconfiguration and energy efficiency upgrades.

II. Structural revolution: the fusion of modular design and smart accumulation

​1. Vertical layered architecture​

• ​dynamical layerTriple speed chain (D/d = 2) to 2-20m/min adjustable speed operation, RFID identification system to achieve model switching response <3s;
• ​conversion layerThe worm gear self-locking lifting mechanism with integrated weighing module and dynamically adjustable tilting angle (5°~28°) guarantees the stability of the 2000kg material sliding;
• ​unpowered layer: The work plate glides by its own weight, and the pneumatic stopper enables free beat operation, increasing the operation efficiency by 30%.

​2. Innovations in space folding​

Wuxi brake pad factory case in point:

• 60 metre linear production line → compressed to a 14 x 6 metre U-ring layout;
• pass (a bill or inspection etc)Jack-up transplanter + double cycleDesign, return to the board air travel reduced by 70%, saving 240,000 yuan in annual electricity costs;
• The distance between the workstations is dynamically adjustable ±15cm, and the time taken to reorganise the production line has been reduced from 3 days to 4 hours.

III. Intelligent control: the leap from PLC to edge decision-making

Wuxi companies are promoting the multiplier chain system to theThree-layer intelligent architectureEvolution:

• ​base control layer: Pneumatic stopper + PLC timing lock (±0.5s precision) to guarantee the accurate stopping of the workpiece board;
• ​IIoT Perception Layer: Strain sensors monitor chain wear in real time, with a pre-maintenance accuracy of 921 TP3T and a reduction in downtime of 701 TP3T;
• ​Marginal decision-making level: LSTM algorithm predicts congested nodes and triggers diversion commands 5 minutes in advance, increasing production line throughput by 40%.

​Examples of energy efficiency breakthroughs: Deployment of a dynamic gravity compensation system in an electronics factory to automatically optimise the tilt angle through real-time weighing feedback, with a speed reduction to 1m/min during no-load hours.Annual electricity saving of 370,000 kWh--Equivalent to the annual electricity consumption of 300 households.

IV. Industry customisation: the leap from precision electronics to heavy manufacturing

​Electronic assembly area​

• Anti-static roller (surface resistance 10⁶-10⁹Ω) + ionic wind dust removal module, meets the standard of class 1,000 dust-free workshop;
• Repeatable positioning accuracy of ±0.5mm for tooling boards, SMT placement yield increased to 99.5%.

​Car Heavy Duty Scenarios​

• 42CrMo alloy steel chain (compressive strength ≥1080MPa) supports the engine block;
• Thermal expansion compensated guides offset ±2mm deformation, robot tightening torque error <5%.

​Food & Pharmaceutical Applications​

• Laser welded seamless rails + titanium dioxide photocatalytic coating, microbial residue risk reduced by 90%;
• NSF H1 certified grease + HACCP compliant design with FDA flight inspection.

V. Selection guide: beyond the parameter table of practical considerations

​1. Load-velocity balance equation​

make a copy of
Actual efficiency = theoretical speed × (1 - friction loss rate)  

The loss rate steepens to 121 TP3T when the load exceeds the design value of 301 TP3T;
WCHE4 chain is recommended for heavy-duty scenarios (allowable tension 0.88kN).

​2. Environmental adaptation matrix​



parameters
Electronic workshop programme
Food Factory Programme




​temperature and humidity​
25±2°C/45%RH
-30°C/anti ice crystallisation coating


​cleanness​
Thousand level dust free + ionic wind
HACCP certification materials


​Explosion-proof requirements​
Static dissipation＜0.1s
Methane sensor linkage disconnect



​3. Design for extensibility​

​Modular splicing: 38.1mm pitch chain supports 2 metre unit extension;
​three-dimensional streaming: U-shaped corner embedded in the jacking transplanter for three levels of material flow.


Self-questioning: four questions for corporate decision-making
​Q1: Does the ring layout limit production line modification?​

​Modular aluminium profiles break the deadlock::

Travostar offers standard profiles such as 1001118, HLX-100, etc., which support quick splicing of 2-metre units;
Existing workstations can be retrofitted with visual inspection modules (one factory upgrade only stopped production for 6 hours).

​Q2: How to verify the reloading security?​

​Third-order stress test criteria::

1.5 times the design load for 24 hours of continuous operation (3000kg required for nominal 2000kg);
Laser velocimeter detects growth rate fluctuations <0.5%;
Emergency stop braking distance <0.8 metres.

​Q3: How does the food line achieve zero risk of contamination?​

​Three defence system construction::

Nano hydrophobic structure (liquid contact angle > 150°);
The UV sterilisation module is embedded in a lifting mechanism;
The number of monthly microbiological sampling sites increased to 32.

​Q4: Will the higher initial investment pay for itself?​

​Efficient Betting Agreements New Business::


The head supplier promises to compensate for the difference in electricity costs if the actual energy saving is <95% target value;
The Wuxi case shows.Space compression + reduced energy consumption leads to 14-month payback.


​Material revolution ahead: Breakthrough data on carbon fibre-titanium alloy composite rollers in the lab - density of only 1.8g/cm³ and 3 times higher wear resistance. When coupled with a maglev drive, the mechanical losses will be close to zero.Energy conversion rate jumps from 68% to 95%, completely reconfiguring the laws of energy efficiency in industrial conveyance.