English (UK) 
简体中文
▍一、单倍速双层链的本质差异
The core difference between a single speed chain and a traditional triple speed chain is thatNo speed increase designIn the single speed structure, the chain moves at exactly the same speed as the loaded pallet. In the single speed structure, the chain moves at exactly the same speed as the loaded pallet, while the triple speed chain achieves pallet speeds up to three times the chain speed by combining large and small rollers (e.g., a ratio of R/r = 1.5). This design makes single speed chain more suitable forScenarios that do not require high speeds but stable conveyingThe main purpose of the system is to provide a high level of quality, for example in the assembly of heavy components or in the production of precision instruments.
Personal Opinion: Current industrial automation is overly pursuing high speed, but the bottleneck in many scenarios lies in the process beat rather than the conveying speed. The "deceleration" characteristic of single-speed chain provides a time window for high-precision work, which is the most important factor forRebalancing efficiency and quality.
▍二、双层结构的空间突破与单倍速的结合
The double-deck doubler chain consists of an upper and lower track:
- upper class: Main conveying of the loaded pallets, in conjunction with a stopper for station pausing;
- lower strata: Dedicated toEmpty board reflowThe upper and lower cycles are achieved by means of a plate return machine;
- core component: Includes jacking cylinders, linear guides, and drive chains to ensure the stability of the vertical transfer of the workpiece.
The combination of a single speed and a double layer, the essence of theA pragmatic programme of space for efficiencyFor example, in the automotive welding workshop, the upper layer conveys the engine cylinder at a uniform speed of 0.5m/s. For example, in the automotive welding shop, the upper layer conveys the engine block at a constant speed of 0.5m/s, so that workers can complete quality inspection comfortably; the lower layer synchronises the recovery of empty plates, avoiding the traditional single-layer line of the body of the empty journey occupies an area.
▍三、成本与性能的博弈：单倍速双层的优劣势
Advantageous profiling.
- space compression: The same capacity occupies 40% less than the single-layer line, which is especially suitable for the renovation of old factory buildings;
- Maintenance SimplifiedNo speed increase roller structure to reduce the failure rate, the self-lubricating characteristics of engineering plastic rollers to reduce the frequency of maintenance;
- Load AdvantageCarbon steel chain plate can load up to 800kg/m, which is far beyond the 300kg/m limit of surface triple speed chain.
Challenge Profiling.
- speed limitations: Maximum conveying speed ≤1m/s, unable to match fast beat scenes such as electronic assembly;
- Installation complexity: Precise calibration of the parallelism of the double-layer tracks is required, and the commissioning cycle is extended by 50% compared to a single-layer line;
- conversion cost: Initial investment is 351 TP3T higher than single-layer line, but life cycle return (LCCR) is up to 2001 TP3T in heavy industry.
Data InsightAfter an agricultural machinery production line switched to single-fold double-layer chain, although the conveying speed was reduced by 25%, the overall efficiency was increased by 18% due to the reduction of handling equipment and personnel.
▍四、应用场景的精准适配
The applicability of single-multiplier double-layer chains is highly dependent on scenario characteristics:
- Heavy industryFor example, if the chassis of construction machinery is assembled, the work plate needs to carry a 2-tonne gearbox, and the stability of single-fold speed is far better than that of high-speed chain;
- precision manufacturing: In medical device filling lines, uniform speed delivery ensures no spillage of medication;
- Hazardous chemicals handling: Anti-static chain + even movement to avoid friction sparks.
Guide to avoiding the pitFor scenarios such as consumer electronics assembly, where <30 second beats are required, triple-speed chains should be preferred; whereas for food packaging lines, where hygiene regulations restrict the use of lubricants, a single-speed, open chain structure is easier to clean.
▍五、选型决策的关键参数
Three core data need to be accounted for before implementation:
- Load tension formula::
F = 9.8 × [(q₁ + q)L₁f₁ + q₂L₂f₂ + (q₂ + q)L₂f₃]
(q: chain weight; q₁/q₂: material distribution/stacking weight; f: friction factor) - power calculation::
Power(kW) = (Tension(kN) × Chain speed(m/s)) ÷ 54.5 - Sprocket AdaptationThe number of teeth ≥ 10 to avoid jumping teeth, the pitch is recommended 38.1mm to enhance the tensile strength.
case (law): The new energy battery pallet line was designed by reducing the coefficient of friction f₃ from 0.16 to 0.08 (using oiled nylon rollers) and the motor power from 1.5kW to 0.75kW.
▍六、智能化升级的隐藏潜力
Although the single-speed chain is considered "basic", its double-layer construction leaves the door open for intelligence:
- jacking and panning machine: To realise cross-line body transfer, together with the vision system for automatic triage of defective products;
- ID Chip for Workbench: RFID chips are implanted in the lower layer of empty boards to track turnover in real time;
- Predictive maintenance: Monitoring of constant tension fluctuations in single-speed chains to anticipate sprocket wear.
A personal view: industry 4.0 is not about blindly pursuing high speeds, but ratherPrecise control of the production rhythm. By adding a PLC beat controller to a single-fold double-deck chain, a home appliance company increased capacity by 22% at the same speed - simply by eliminating station waiting.
▍自问自答：单倍速双层链的实战疑问
Q1：When space is limited and high-speed production is required, can a double-layer triple-speed chain be used as an alternative?
Technically feasible, but poor economy. The double-layer structure of the triple-speed chain costs 60% more than the single-speed version, and high-speed operation leads to a sharp increase in the failure rate of the board return machine. A better solution is the combination of "single-layer triple-speed + three-dimensional warehouse".
Q2: Why would heavy industry prefer a single speed over a more robust 2.5x chain?
The speed increasing mechanism of 2.5 times speed chain increases the number of rollers and is prone to jamming in dusty environments. Single speedNon-boosting design reduces 40% moving partsIt is more suitable for harsh working conditions.
Q3: How to break the pain point of high maintenance cost?
adoptionModular design: Pre-assembled the board return machine jacking unit, drive motor, etc. into a quick release module, the maintenance time was compressed from 8 hours to 1.5 hours.
