The core technology and application analysis of the customised circulating speed doubling chain production line

In the wave of industrial automation, the Circular Doubling Chain production line is becoming the core carrier of the efficiency revolution in manufacturing. Its uniqueDifferential Principle--Through the diameter difference between the roller and the roller to achieve the workpiece moving speed is 2-3 times the speed of the chain itself (common timespeed ratio is 2.5-3 times), so that the production line in theSimultaneous operation of multiple work stations in limited spaceThe traditional assembly line's beat constraints have been completely changed.

​I. Core technical advantages of the speed chain​

  1. ​Efficient Carrying and Precise Positioning​

    • ​Heavy-duty capacity breakthrough: Designed with steel rollers and high-strength chains, the maximum load of a single section of line can be up to 2200kg (e.g. heavy parts conveying such as engines, gearboxes, etc.).
    • ​Micron-level precision control: Pneumatic/electrical stopper cooperates with the positioning pin to achieve ±0.05mm repeatable positioning accuracy, which significantly reduces the manual alignment error.

  2. ​Dynamic Adaptability and Low Maintenance Design​

    • The automatic chain tensioning system can cope with the expansion and contraction deformation caused by long-term operation, with self-lubricating kit and anti-static design.Maintenance frequency reduced by more than 40%.
    • The modular construction supports the quick replacement of damaged parts (e.g. individual rollers or links) and avoids downtime of the entire line.

​II. Key dimensions of customised design​

​1. Load and material selection​

  • ​light load scenario(<200kg): Engineering plastic rollers + lightweight aluminium profile frame (e.g. 3C electronic assembly line).
  • ​overloaded scenario(>500kg): Steel rollers + carbon steel frame, sprocket teeth machining accuracy up to IT7 grade.

​2. Layout and spatial optimisation​

  • ​Compact LayoutTurning radius: minimum 300mm, climbing angle ≤15°, adapt to small plant space.
  • ​multilayer recirculation systemThree-dimensional conveying (e.g. multi-layer line linkage in automotive component factories) is achieved by means of a jacking transfer machine + a vertical hoist.

​3. Integration of intelligent control systems​

  • PLC (e.g. Siemens S7-1200) based co-control with integrated RFID workpiece tracking, robot linkage interface.
  • ​Real-time fault diagnosis: Monitor motor temperature and current fluctuations for early warning of potential failures (e.g. chain overload slippage).

​Third, the whole process of customisation link analysis​

  1. ​Demand Precision(of project cycle 30%)

    • Live video documentation of existing production line bottlenecks to quantify parameters:
      • Conveying speed (5-20m/min adjustable)
      • Workstation spacing (1-1.5m/workstation)
      • Environmental requirements (dust/anti-static rating).

  2. ​Scheme simulation validation​

    • The dynamics are simulated by SolidWorks Motion to optimise the acceleration profile and avoid workpiece displacement due to rapid stops.
    • ​Differential Ratio Verification: Match the speed increasing effect with the roller diameter and chain pitch (e.g. 3 times speed chain needs to meet the roller diameter/roller diameter=3).

  3. ​Manufacturing and Quality Control​

    • Branding of key components (e.g. German IGUS chains, SEW motors) ensures a life span of >100,000 hours.
    • 72 hours continuous load test (full load + 110% overload test), record the number of downtime and positioning drift value.

​IV. Industry Applications and Innovation Cases​

  1. ​Automotive Manufacturing​

    • ​Engine assembly lineHeavy-duty triple-speed chain + jacking rotary table for 360° dead-angle-free bolt fastening, shortening the beat to 90 seconds/unit.

  2. ​3C Electronics Industry​

    • Mobile phone inspection line: anti-static work plate + ± 0.1mm positioning accuracy, compatible with multi-model products mixed line production.

  3. ​New Energy Innovation Scene​

    • Battery PACK line: Integrated automated guided vehicle (AGV) docking port to achieve seamless flow of battery cells from storage to assembly.

​personal viewpoint: The biggest pain point in the current multiplier chain customisation is not the technology itself, but theDisconnect between design and production. Many manufacturers provide standardised modules, but ignore process adaptability. For example, when a home appliance company customised the wire body, it did not take into account the thermal deformation characteristics of the plastic parts, and the high temperature in summer led to frequent offsetting of the positioning pins. Therefore.Recommends the adoption of the "process-equipment parallel design" model at the programme stage: The micro movements of each station (e.g. screw torque requirement, visual inspection angle) are confirmed by the equipment engineer and production supervisor, and then the mechanical structure parameters are back-referenced.

​V. Future developments and challenges​

  1. ​technological trend​

    • ​Flexibilisation is upgraded again: Development of quick-change tooling board systems to support switching of product types within 1 hour (e.g. replacing traditional bolted fixings with magnetic clamps).
    • ​Energy consumption optimisation: Regenerative braking technology recovers deceleration energy and reduces motor power consumption by 151 TP3T as measured.

  2. ​The SME Adaptation Challenge​

    • Traditional customisation is costly (complex lines > 1 million RMB), now derived from theModular Affordable Programme::
      • Adoption of 220V drive motor (not industrial 380V)
      • Wire length ≤ 15 metres (to avoid tensioning failure)
      • Workspace Extension is rented on demand.

​Ask yourself the core question.​
​Q1: Is the speed chain production line compatible with existing old equipment?​
Can be retrofittedTransition Adaptation ModuleFor example, the power pulley section connects the speed multiplier chain with the conventional belt line, and compensates for the equipment drop by means of height-adjustable foot cups (±50mm deviation permitted by actual measurement).

​Q2: How to solve the long customisation cycle?​
adoptionSegmented delivery strategy: Delivery of the 10-metre base line section for commissioning first, with subsequent modules (e.g. jacks and hoists) gradually added during operation, reducing the waiting period for commissioning to less than 2 weeks.

​Q3: How are maintenance costs controlled?​
carry outPreventive Maintenance Kit: 1 chain tension check per month (using a digital tension meter) + 1 roller wear analysis per quarter (based on vibration sensor data), a 60% reduction in maintenance costs compared to traditional breakdowns.

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