Double-deck Speed Chain Conveyor Line in Kunshan: Industrial Innovation for Space Optimisation and Intelligent Conveying

• ​Production level (upper)Standardised height 750mm (±30mm adjustable), with 118 x 100 aluminium profile guide rail and triple speed engineering plastic chain, the working surface width can be customised from 250-900mm, suitable for different product sizes;
• ​Reflux layer (lower): Unloaded pallets throughJacking and lifting mechanismVertical transfer, cylinder positioning accuracy ±0.1mm, closed cycle reduces 30% invalid stroke;
• ​Energy consumption optimisation: The frictional resistance of the lower airboard is only 1/8 of that of a full load, and the measured energy consumption is reduced by 57% compared to a single-ply line.

Personal view: the current manufacturing industry blindly pursues the speed of delivery, but ignores theSpace costs account for 23% of total plant investmentThe Truth. After adopting a double-storey design in an electronics factory in Kunshan, the plant area was reduced by 40% under the same capacity, saving 1.5 million yuan in expansion costs-Space reuse benefits far outweigh incremental speed value.

ralph lauren industry customised solutions: from microelectronics to heavy-duty scenarios

​Electronic precision assembly (e.g. mobile phone camera production lines)​

• ​Anti-static design: The surface resistance of the tooling board is controlled at 10⁶-10⁹Ω to avoid IC chip breakdown;
• ​Electric conveyor technology: Conductive wheel built in the line + work plate conductive row, to achieve online testing and debugging;
• ​Nanoscale braking: Pneumatic stopper + fibre optic positioning, positioning error ≤ 0.1mm, yield rate increased to 99.8%.

​Automotive Heavy Duty Production Line​

• ​Reinforcement of chain platesThe thickness of carbon steel chain plate is increased to 2.2mm, and 3 sets of auxiliary support wheels are added per metre, with a load-bearing capacity of 1.4 tonnes;
• ​Dual drive redundancy: Dual side independent SEW worm motor drives, single side failure still maintains 50% capacity.

​Food & Pharmaceuticals​

• ​Oil-free cleanliness programme: Guide rails coated with 0.3mm molybdenum disulphide, quarterly dry maintenance instead of weekly lubrication;
• ​Material upgrade: 304 stainless steel chain + seamless welding process, FDA 21 CFR 117 certified.

▍智能控制体系：PLC驱动的精敏制造

The Kunshan solution integrates automation control deeply into the conveyor system:

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  ├── **Precise control of the beat**Mitsubishi / Siemens PLC programming to achieve infinitely variable speed regulation (2-20 m / min), electromagnetic speed motor response time <0.3 seconds[.6,8](@ref)
  ├── **Independent management of workstations**: Each station is equipped with a blocker + foot valve, supporting a single point of start and stop without interfering with the operation of the whole line [...3,7](@ref);
  └── **full process traceability**: MES system associates RFID and process parameters of tooling boards, improving the efficiency of defect traceability 90%[...7,10](@ref).  
​case in point: In a power plant, by optimising the timing of station movements and eliminating wasteful waiting at the same conveyor speed, capacity was increased by 22% -Proving that the value of intelligence lies in "precision collaboration" rather than speed alone.

ralph lauren cost-actuarial modelling: long-term returns on customised inputs



Customised dimensions
incremental cost
Payback cycle
implicit benefit




Heavy Duty Reinforcement
+¥230,000/100 metres
<14 months
Downtime losses ↓57%


compression of floor height
+¥180,000/line
Immediate returns
Save ¥1,500,000+ on plant alterations


Intelligent pre-built
+¥320,000/line
<18 months
O&M costs ↓60%


Cleanliness upgrade
+¥90,000/line
<8 months
Clean room energy consumption annual savings ¥ 120,000




▍自问自答：落地昆山的三大实操难题
​Q1: Can double-deck lines be deployed in old factory buildings with a floor height of only 2.8 metres?​


​Triple space compression technology::

① Z-folding return layer (height pressed to 220mm);

② Ultra-thin cylinder (35mm stroke instead of 50mm standard);

③ Carbon fibre work plate (thickness 12mm instead of 18mm steel plate).

※ A lithium battery factory in Kunshan has successfully applied it in a 2.8-metre-high workshop, with a vertical space utilisation rate of 91%.

​Q2: How to balance efficiency and flexibility with frequent production changes?​

​Three Elements of Dynamic Adaptation::

Motorised adjustable tooling plate (±50mm pitch adjustment);
Variable frequency motor (0.3-1.5m/s stepless variable speed);
Quick-change moulds (pneumatic locking + locating pin design).

※ An automobile parts factory has used this to reduce the changeover time from 4 hours to 40 minutes.


​Q3: How to achieve seamless compatibility for multi-brand devices?​

​The triple axe of interface standardisation::

① Mechanical interface: mandatory adoption of ISO 3684 sprocket tooth profile;

② Electrical protocol: Profinet/EtherCAT dual protocol stack is reserved;

③ Data Centre: Unified access to MES system through OPC UA.



ralph laurenExclusive Foresight: The Kunshan Paradigm of the Silent Factory​

When the industry focuses on the "speed race", Kunshan enterprises are using theEngineering plastic chain + vibration suppression guideThe technology has reduced the production line noise from 85dB to 62dB (below OSHA safety threshold). A leading factory's measurement shows that after the noise reduction, workers' communication efficiency is improved to reduce the misoperation rate by 17%, and the maintenance frequency is reduced by 66% due to the self-lubricating property of engineering plastic chain, which reveals a counter-consensus trend---The core indicator of industrial evolution in the next decade may shift from "efficiency" to "human-machine harmony".. As the rumble of steel gears falls silent, the human values on the assembly line will eventually shine again.