Ji'an Ring Doubling Chain: Spatial Reconfiguration and Efficiency Revolution of Ganzhong Intelligent Manufacturing

In the wave of intelligent transformation of manufacturing industry in Ji'an, theRing Roller Doubling Chain LineIt is becoming the core engine of production line innovation. It is not only a vehicle for material transport, but also a means ofMechanical precision designtogether withintelligent controlThe integration of the production of the free control of the production beat has become the key infrastructure for the upgrading of Ji'an speciality industries such as electronic information, new energy, green food and so on.

I. The Mechanical Mystery of Multiplier Chain: Principle of Speed Increase and Structural Innovation

The multiplier chain is named after its uniquePhysical growth rate mechanism--When the chain is running at a constant speed (v₀), the actual speed (v) at which the work plate is moving can be up to 2-3 times the speed of the chain. The core formula for this is:
v = (1 + D/d) × v₀
(D is roller diameter, d is roller diameter)

This growth rate is achieved through the synergy of three sets of precision components:

growth rate unit (computing): The difference between the diameter of the roller (D) and the diameter of the roller (d) constitutes the basis for speed multiplication, which is mostly used by Gian enterprises.D/d=1.8~2.2golden ratio
load-bearing structure: Tandem assembly of inner/outer plates and pins, with clearance between pins and inner plates to ensure flexible chain bending.
Material InnovationNylon rollers are used in light load scenarios (e.g. SMT mounter line in an electronic factory in Ji'an) and heavy load environments.Surface hardened alloy steel rollers(hardness HRC58-62), single point load capacity up to 300kg

In a circular layout, theClosed-loop guideway designZero idle cycle is achieved for the workpiece board. Take a lithium battery factory in Ji'an as an example, the work plate automatically returns to the starting point within 8 seconds after completing the electrode assembly through the jacking and transplanting mechanism, and the production line covers an area of 37%.

II. Innovative Practices of Ji'an Enterprises: Spatial Optimisation and Connection Technology Breakthroughs

1. Spatial reconfiguration of the circular layout

Faced with the problem of tight industrial land use in Ji'an, local enterprises have developedVertical layered ring system::

Three-layer three-dimensional conveying: Upper assembly, middle inspection, lower rework, 2.6 times higher capacity per unit area
Compact turning design: Adoption of R600mm small radius curved rails, saving space in the turning area compared with the traditional R1200mm scheme40%

2. Localised innovation in connectivity technologies

For Ji'an's high humidity environment (annual average RH>80%), the engineers developed theComposite connection process::

vibration stationSide plate pin connection for increased shear strength of 65% and maintenance-free cycle of 8,000 hours.
assembly station: Reduced maintenance costs by switching to bolted connections 40%, supports quick station adjustments
Anti-corrosion enhancement: chain plate micro-arc oxidation treatment + seams filled with food-grade silicone, salt spray test >720 hours

Third, industrial adaptation: the technical landing of Ji'an's characteristic scene

1. Electronic information industry: micro-precision assembly

In Ji'an touch screen production line, the speed chain system achieves three major breakthroughs:

Sub-millimetre positioning: Blocker with Hall sensor, positioning error ≤±0.1mm
electrostatic protection: Carbon fibre workpiece surface resistance of 10⁶-10⁹Ω to avoid breakdown of microcircuits
Modular extensions: 25% power margin reserved to support future line additions

2. New energy batteries: heavy-duty high-temperature challenges

For the special requirements of lithium battery transport, the Gion programme contains:

Explosion-proof design: Positive pressure ventilation system embedded in the guide rail, eliminating the accumulation of electrolyte volatile gas
temperature controlLiquid-cooled piping integrated in aluminium alloy rail, temperature control precision ±3℃ (far exceeding the industry standard of ±5℃)
Safety Redundancy: Dual chain parallel design, 0.5 seconds automatic switching in case of failure

3. Green Food Processing: Balancing Hygiene and Efficiency

The application case of Ji'an Rice Products Processing Plant shows:

Fully sealed rails: HACCP certified, microbiological residues <50CFU/cm².
Water saving systemSelf-cleaning nozzles with integrated chain plate gap reduce water consumption for cleaning by 60%
AI Sorting: Near infrared spectrometer + speed chain dynamic speed regulation, defective product rejection speed up to 0.4 seconds/piece

IV. Techno-economics: validation of the effectiveness of Gian enterprises

Local project data reveals significant advantages when compared to conventional conveyor lines:

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+---------------------+--------------+-------------------+
| Indicators | Conventional Drum Lines | Ring Doubling Chain System |
+---------------------+--------------+-------------------+
| Space utilisation | 52% | 88% (+69%) |
| Unit energy consumption (kWh/tonne) | 8.1 | 5.2 (-36%) |
| Interval between failures (hours) | 280 | 1,300 (+364%) |
| Changeover Adjustment Time | 4.5 hours | 30 minutes (-89%) |
+---------------------+--------------+-------------------+

Dynamic Accumulation FunctionCompletely reconstructed the production beat - the practice of a motor factory in Ji'an shows that operators achieve local suspension and continuous operation of the whole line through foot blockers, which reduces the efficiency fluctuation rate from 28% to 4%.

V. Selection and Maintenance: A Guide to Adaptation for the Gian Environment

Material Selection Matrix

take	Chain material	Roller type	Protection process
electronics assembly	Nickel-plated alloy steel	POM engineering plastics	Antistatic coating
food processing	06Cr19Ni10 stainless steel	Glass fibre reinforced PA66	Silicone seam sealing
Chemical environment	Hastelloy C276	Ceramic Composite Roller	micro-arc oxidation process

Ji'an Speciality Maintenance Strategy

Tension control: Weekly testing of chain elongation during the rainy season (threshold <1.5%)
Lubrication optimisation: Reduced cycle time up to 48 hours with lithium grease + molybdenum disulphide composite lubricant in high humidity environments
Preventing replacement: 6,000 hours mandatory replacement of engineering plastic rollers (stricter than standard 8,000 hours)

VI. Future Trends: Integration of Intelligent and Green Manufacturing

The Gian Doubling Chain system is undergoing a triple evolution:

Perceptual Layer Upgrade: Embedded RFID chips in the chain plate, real-time tracking of workpiece process parameters (e.g. 12% yield improvement in a PCB factory)
energy regenerationRegenerative braking system converts deceleration kinetic energy into electrical energy, with a recovery efficiency of 79%, saving more than 180,000 yuan of electricity per year on a single line.
digital twin: Virtual model synchronisation to optimise physical line body beats (e.g. 80% reduction in downtime for a project in the Jinggangshan Economic Development Zone)

According to Ji'an Bureau of Industry and Information Technology, the city will have 40% production lines deployed in 2027AI dynamic scheduling system--Optimisation of conveyor beats through machine learning has resulted in an OEE of over 951TP3 T. This fusion of "mechanical precision + data intelligence" is reshaping the competitiveness of Ganzhong's manufacturing industry! Kernel.

Analysis of core issues

Q1: How can the ring layout solve the problem of tight land use for enterprises in Ji'an?

A: AdoptionClosed-loop topology eliminates end idle zonesWith the combination of vertical three-layer conveying, the capacity per unit area is increased by 2.6 times; R600mm small radius curved rail design further compresses the space in the turning area 40%, which is especially suitable for the transformation of old industrial parks.

Q2: Why does Gian Foods Factory pay special attention to the hygienic design of the multiplier chain?

A: itsSeamless rail constructionEliminate microbial breeding dead space, in line with GB 14881 food safety standards; self-cleaning nozzle and silicone sealing process makes microbial residues <50CFU/cm², far below the industry limit of 100CFU/cm².

Q3: Which local industries are most in need of priority introduction of this system?

A.electronic information(micro-precision positioning).Lithium new energy(explosion-proof requirements).Processing of rice products(health standards) three Ji'an pillar industries benefit most significantly. 2025 local market size is expected to exceed 1.5 billion yuan, with a compound annual growth rate of 22%.