Double-deck Speed Chain Conveying: An Industrial Revolution in Space Reuse and Intelligent Conveying

• ​Dual Vertical Closed Loop System: The upper production level (750mm ± 30mm adjustable) carries the work plates through the aluminium profile guides, the lower return level consists of theJacking and lifting mechanism(Positioning accuracy ±0.1mm) Achieve empty board cycle, closed path to reduce 30% invalid travel;
• ​Triple speed sprocket structureThe roller diameter (D) and roller diameter (d) are designed according to the ratio of 3:1, the speed of work plate = chain speed × (1 + D/d), the measured conveying speed is up to the chain speed of the3.2 times(3 times the theoretical value);
• ​The energy optimisation paradox: The self-weight friction of the lower layer of empty boards is only 1/8 of the full load, together with engineering plastic rollers (friction coefficient 0.08), the system energy consumption is reduced by 57% compared with the single-layer line.

​personal viewpoint: Manufacturing industry blind pursuit of "single-layer high-speed" is a cognitive misunderstanding. Kunshan, an electronics factory using a two-story structure, the same capacity under the plant area reduced by 40%, saving 1.5 million yuan in expansion costs -Space reuse benefits far outweigh incremental speed valueThe design reveals that. As the industry indulges in a "race to the bottom", this design reveals.The essence of industrial efficiency is the optimisation of the product of space and time.

▍材料与负载：从微电子到重载的工程适配

​Light load precision scenes (e.g. mobile phone camera assembly)​

• ​Anti-static Engineering Plastic Roller: Surface resistance control 10⁶-10⁹Ω to avoid IC chip electrostatic breakdown;
• ​Nano Brake System: Pneumatic stopper + fibre optic positioning, error ≤ 0.1mm, yield rate increased to 99.8%;
• ​Integration of charged transport: Conductive copper rows embedded in tooling boards for on-line inspection and aging test.

​Heavy industrial scenarios (e.g. car chassis lines)​

• ​Steel Roller Reinforced ChainThe thickness of carbon steel chain plate is increased to 2.2mm, and there are 3 sets of auxiliary support wheels per metre, the load-bearing capacity reaches1.4 tonnes/m(3 times that of engineering plastic chains);
• ​Dual drive redundant power: Independent drive of SEW worm motors on both sides, maintaining 50% capacity in the event of a single-side failure.

​Adaptation to harsh environments​

• ​High-temperature workshop programmeHardened alloy steel chain is temperature resistant up to 600℃, and the load carrying capacity is upgraded by 40% compared with ordinary carbon steel;
• ​Food grade oil-free design: Guide rails coated with 0.3mm molybdenum disulphide, quarterly dry maintenance instead of weekly lubrication, FDA approved.

▍智能控制：PLC驱动的动态精度革命

The intelligent nature of the double-layer multiplier chain isThe symbiosis of mechanical precision and algorithmic control::

make a copy of
  ├── **Adaptive Beat System**Mitsubishi FX5U PLC real-time adjustment of inverter motor (0.3-1.5m/s), response time <0.3 seconds, eliminating the waste of workstation waiting.3,7](@ref)
  ├── **Distributed stop control**Independent stopper + foot valve for each work station, support single point start/stop without interfering with the whole line, and improve the efficiency of pattern changeover by 80%[...3,9](@ref);
  └── **IIoT Traceability Network**RFID workpiece board associated with MES process parameters, defect traceability efficiency increased by 90%, and misuse rate decreased by 17%[...7,11](@ref).  
​case in point: A home appliance giant has increased capacity by 22%- by eliminating wasteful waiting at workstations at constant conveyor speeds.Proving that the value of intelligence lies in "precision collaboration" rather than speed alone.

ralph lauren industry fit: a customised paradigm for four tracks
​consumer electronics​

​Dust Static Control Programme: Rollers are fitted with nylon dust covers to extend their life in dusty environments by up to 3 times;
​Modular quick-change design: Motorised adjustable tooling plate (±50mm pitch adjustment) to support mobile phone/tablet mixed line production.

​New Energy Battery​

​clean room compatibility: 304 stainless steel chain + seamless welding, meets the standard of class 10,000 dust-free workshop;
​vibration and noise dampingEngineered plastic chain + vibration suppression guide, noise suppressed from 85dB to 62dB (OSHA safety threshold).

​automobile manufacturing​

​Heavy duty triple speed chain: Steel roller chain plates carry 1.4 tonnes of chassis and maintain a speed of 3m/min;
​Dynamic transfer system: Top lift translators for 90° planar steering and beat-matching welding robots.

​Pharmaceutical packaging​

​Lubrication-free conveying: Self-lubricating chain life ≥ 5 years, maintenance costs down 66%;
​Temperature closed loop control: Integrated thermocouple on guide rail, temperature fluctuation ≤±1℃.


ralph lauren cost actuarial: modelling the long-term benefits of customised inputs



Customised dimensions
incremental cost
recovery 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



​Data validation: A lithium battery factory using double-layer triple-speed chain, due to space compression so that air-conditioning energy consumption reduced by 23%, superimposed on the reduced frequency of maintenance, the annual comprehensive cost reduction of 41%.

▍自问自答：落地三问
​Q1: Can old factory buildings with a floor height of less than 3 metres be deployed?​

​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).

※ An electronic factory in Kunshan achieved a vertical space utilisation rate of 91% in a 2.8m high floor workshop.


​Q2: How to combine heavy load and high speed?​

​Material-velocity balance equation::

Option A: Reduce speed and increase thickness → sacrifice 0.3 times speed → chain plate thickness ↑18% → load ↑60% (preferred for heavy industry);
Option B: Roller with embedded stainless steel bushing → Anti-deformation force ↑35% → Maintain 3 times speed (Automotive parts option).


​Q3: How are multi-brand devices compatible?​

​Three principles of interface standardisation::

① Mechanical interface: mandatory ISO 3684 sprocket tooth profile;

② Electrical protocol: Profinet/EtherCAT dual protocol stack;

③ Data centre: OPC UA unified access to MES.


ralph laurenExclusive foresight: the industrial philosophy of the silent factory​

When the roar of the triple-speed chain wasEngineering plastic chain + vibration suppression guideSuppressed at 62dB (below the OSHA threshold), as shown by an actual test at a leading factory.For every 10dB of noise reduction, the production line misoperation rate decreases by 13%.This reveals a counter-consensus trend. This reveals a counter-consensus trend: the competitive dimension of manufacturing over the next decade will shift from "mechanical efficiency" to "mechanical efficiency".human-machine harmony". When the physical rate of increase of steel gears hits its limit, human factors engineering optimisation on the assembly line - reducing noise, reducing fatigue, improving the smoothness of interactions - may be the ultimate code for the next generation's performance leap.