Customised double-deck speed chain conveyor lines: the fusion of spatial revolution and smart manufacturing

• ​upper production layer: AdoptionTriplex chain (D/d=2)Conveying workpieces at a measured speed of 6m/min (base chain speed 2m/min) to meet the needs of high tempo such as automotive welding;
• ​lower return layer: Closed-loop return of empty workpiece plates driven by independent motors.Save 50% flat footprintThe compact layout of the microfactory is suitable for this purpose;
• ​Millimetre accuracy of the loader: The pneumatic jacking mechanism is optimised by 3D motion simulation, with an error of ≤0.5mm, eliminating manual handling 15% efficiency loss.

​personal viewpoint: Conventional single-deck lines require an 8-metre turning radius, whereas customised double-deck structures are built through theVertical space folding, turning mechanical complexity into a land cost advantage - when the unit price of industrial land exceeds RMB 5,000 per square metre, the ROI (return on investment) of this replacement strategy can be shortened to 18 months.

Second, the whole process of customisation: from demand anchoring to delivery closure

​1. Precise mapping of needs​

• ​Scene DiagnosticsAnalyse existing production line bottlenecks (e.g. imbalance in the beat of the SMT patch segments in electronic factories) through on-site video recordings, and clarify core parameters such as load (≤500kg at a single point), speed (5-15m/min), and cleanliness (e.g. microorganisms in the pharmaceutical industry ＜0.05CFU/cm²);
• ​cost game point: The choice between a conventional line body ($50,000 - $200,000) and a complex customised line (million-dollar level) needs to be assessed in terms of the risk of a surge in maintenance costs of 351 TP3T due to the share of non-standard modules > 301 TP3T.

​2. Virtual validation first​

• ​Parametric modelling: CAD/CAE construction of adjustable digital model with 200+ link libraries preset (Fig. 1);

Image Code
graph TB
A[Material weight] --> B(Chain selection)
C[Beat request] --> D (Doubling Ratio Design)
E[Plant dimensions] --> F (floor layout)
B & D & F --> G{{3D dynamic simulation}}
G --> H[Output bias load resistance programme]
▲ Customised Design Decision Tree

​Gravity Field Simulation: The deformation of the support column during the conveying of 1.2 tonnes of automobile parts is judged to be ≤0.3mm, which avoids overloaded chain breakage accidents;
​3D Printing Pilot: Manufacturing cycle time for complex loadshifting mechanism parts from 15 days to 3 days, and trial-and-error cost reduced by 47%.


III. Intelligent control: data flow-driven conveyor nerves
​1. Three closed-loop dynamic regulation​

​tacho loop: Inverter compensates current fluctuation in real time, speed deviation ≤ 5%;
​position loop: RFID positioning + PLC synchronised blocker, timing error ≤ 0.1s;
​stress ring: Strain gauges monitor the deformation of the support column, with an automatic speed reduction of 0.3mm over the limit.

​2. Functional extension matrix​



​module (in software)​
​Technical programme​
​Industry Cases​




​Dynamic Sorting​
Jacking transplanter + visual positioning (±0.2mm)
3C Electronic AOI False Judgement Rate ↓90%


​aseptic protection​
304 stainless steel chain + UV sterilisation module
Pharmaceutical packaging microbiological residue compliance 100%


​Anti-static system​
Conductive wheel + carbon brushes (resistance ≤ 10^6Ω)
Chip Factory ESD Damage Incident ↓95%




​counterintuitive insight: Triplex chains require servo motors in heavy-duty scenarios, otherwise there is an increased risk of workpiece deflection 50%--The balance between speed and accuracy is essentially a coupled game of mechanical dynamics and control algorithms..


IV. Industry tailor-made programmes: cross-border adaptation from automotive to food
​1. Automotive welding scenarios​

​Heavy Duty Reinforcement: Alloy steel chain (tensile 2000MPa) + hydraulic buffer limit, carrying 1.5 tonnes frame deflection <1mm;
​space foldingDouble-layer structure replaces the traditional U-shaped line, reducing the production line footprint by 60%.

​2. Food baking scenarios​

​Temperature-resistant innovations: Engineering plastic roller (150℃ resistant) + food grade self-lubricating chain, baking line downtime rate ↓65%;
​Anti-pollution designSealed cover + roller dust cover to prevent the "abrasive paste effect" caused by the mixing of grease and dust.

​3. Electronic assembly scenarios​

​Flexible wire change: Modular tooling plate ±90° rotation, product changeover within 1 hour;
​traceability system: RFID binding process data, quality issues traceability efficiency increased by 80%.


V. Full life cycle maintenance: from lubrication strategy to predictive intervention
​Daily maintenance​

Magnetic scraper to clean up track debris (3 times more efficient in dusty environments);
Carbon brush thickness monitoring (<2mm automatic alarm replacement).

​Key items per month​

Deflection calibration of the tensioning device (manual press deflection ≤ 3mm);
Sprocket tooth gap injected with lithium-based high-temperature resistant grease (life extension of 2.8 years).


​Exclusive data:: An air-conditioning plant through a customised maintenance programme.Conveyor line monthly downtime from 8 hours to 0.5 hoursBut WARNING: Weekly lubrication in humidity > 70% environments will accelerate wear - need to switch to a dry lubrication strategy.


Self-questioning: penetrating the customisation fog
​Q1: How do you control the cost of customisation without losing control?​

A: Third-order cost compression strategy:


​Cost reduction in light load areas: Nylon chain + single speed drive for non-critical sections, cost ↓30%;
​Interface standardisation: Quick release track + ISO electrical interface, retrofit cost ↓50%;
​Small batch verification: Do a 10-metre sample section test first to avoid the loss of full rework.

​Q2: How to balance speed and stability in heavy load scenarios?​

A: 3D simulation-based balancing scheme:

​Step-by-step speed control: 3x speed (6m/min) on straight sections, reduced to 1.5x on corners to prevent tailgating;
​composite material: Noise reduction with engineering plastics for light load areas and switching alloy steel sprockets for heavy load areas;
​pressure shunt: Hollow support columns direct the 60% loads to the free-standing steel frame.


As the manufacturing industry enters the era of "space is cost, data is an asset".The core competence of customised double-layer speed chains has shifted from mechanical accuracy to the product of "spatial reconfiguration capability x data closure efficiency".. However, those 0.01mm assembly tolerances not covered by 3D simulation are still a reminder.The essence of smart manufacturing is not the perfect extrapolation of the virtual world, but the precise domestication of uncertainty in the physical world.
​Table of key technical parameters for the customisation of double-layer speed doubling chains​



parameter category
Scope of customisation
Special Scenario Expansion




​Line width​
250-900mm
Explosion-proof environment up to 1200mm


​floor height adjustment​
500-1000mm
Automotive welding line 1500mm


​Conveying speed​
2-20m/min
Electronic sorting line 30m/min


​octave ratio​
1.5-3 times
Heavy duty scenarios limited to 1.8 times


​position accuracy​
≤0.5mm (pneumatic jacking)
Visual aid ±0.2mm


​Maximum load​
200-2000kg
Automotive Work Rack 3000kg



[cite source]

:: Space utilisation and structural parameters of double-deck speed chains

: Virtual validation and cost control in the customisation process

: Case of traceability system and production efficiency improvement

:: Optimisation of industrial land costs and production line layouts

:: Counterintuitive discovery in maintenance strategies

: Special materials for the pharmaceutical and food industries

: Expansion of functional modules and intelligent upgrades