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I. Design Principle and Structural Composition
Upper and lower circulation double layer speed multiplier chain is a type of chain that passes through theUpper level production, lower level returnAn automated system for closed-loop conveying. The core design consists of two parallel speed doubling chains running in opposite directions: the upper layer carries the pallets for product processing, and the lower layer returns the empty pallets to the starting point, forming a continuous cycle. This structure breaks through the space limitation of the traditional single-deck conveyor line, and more than doubles the productivity of the same area.
Key Component Parsing.
- drive system: PLC-controlled hollow shaft motor or horizontal motor is adopted to ensure smooth chain operation through the active sprocket and the driven sprocket with the tensioning mechanism.
- Tooling Board SystemCustomised pallets (PVC, carbon steel or Bakelite) are equipped with guide wheels and clamps to carry the product and to adapt to the incremental speed characteristics of the multiplier chain. The width of the pallet must be 5mm less than the gap of the aluminium profile guides to ensure smooth running.
- transfer mechanism: Lifting device (cylinder or servo linear module driven) connected to the upper and lower levels to achieve vertical transfer of the workpiece boards. The patented design incorporates ball limit slots and guide crossbars to prevent mechanical interference.
- Positioning and blockingCylinder-driven pendulum stops are distributed at key nodes on the upper and lower levels, and the torsion spring reset controls the dwell beat of the workpiece plate to meet the demand for time-sharing assembly.
II. Analysis of the unique speed doubling mechanism
The "growth rate" feature of the multiplier chain stems from itsPhysical structure design. When the chain is moving at a speedvAt a constant speed, the actual travelling speed of the work plate can be up to the chain speed of the2.5 or 3 times(i.e. triplex or 2.5x chain). This effect is realised by the difference in diameter between the rollers and the roller:
make a copy ofTheoretical growth rate ratio formula: v = v₀ × (1 + D/d) (D is roller diameter, d is roller diameter)Due to the rolling friction between the engineering plastic rollers and the steel guideway and the rigid coupling effect of the rollers-rollers under load pressure, the workpiece plate acquires a superimposed acceleration. Practical applications need to control theGuideway flatnesstogether withChain precisionIn order to avoid the loss of speed increase due to sliding friction.
Third, the depth of the industry application scenarios to adapt
The technology has penetrated into high-precision assembly in many fields:
- Electrical and electronic industry: In the TV/laptop assembly line, the tooling board integrates a conductive wheel with power supply from a sliding contact line for in-line inspection.
- automobile manufacturing: The engine assembly line utilises itsLoad capacity (up to several tonnes)Supporting heavy components, the patented design of the support platform distributes the downward pressure of the press and prevents chain deformation.
- Small parts machiningDouble-layer structure is compatible with lightweight materials (e.g. mobile phone parts), and the lower layer can be synchronised with the second line of reworked products when returning to the flow.
personal insightThe double-layer design, as opposed to the traditional ring speed chain, is achieved by theVertical space reuseSolve the electronic factory "high cost of flooring, production line extension limitations" pain points, especially suitable for China's manufacturing intensive upgrade needs.
IV. Innovative patented technology breakthroughs
For the doubler chain in the laminating processPressure and deformation hidden dangerSungBang Precision Patent (2023) proposes a triple innovation:
- Spring Guide Tray Assembly: When the support plate is under pressure, the support columns are crimped through the pallet perforations to the bearing platform, transferring the 80% pressure to the independent steel frame.
- Weight-reducing support columns: Hollow cylinders with openings in the side walls to reduce inertial energy consumption while safeguarding compressive strength.
- Hoist safety redundancy: Servo linear modules drive the roller rows, together with casters with brakes to achieve millimetre positioning and avoid lifting and tilting.
V. Comparative Advantages and Suggestions for Selection
| dimension (math.) | Double Speed Chain | Ring Speed Chain |
|---|---|---|
| spatial efficiency | Save 40% or more in floor space | Need space for a larger ring layout |
| Load Adaptability | Optimised for heavy loads (steel rollers) | Medium loads predominate |
| Maintenance complexity | Periodic calibration of the double-chain balance is required | Single-chain construction for easier maintenance |
| Applicable process | Multi-process segmented assembly | Continuous cycle processing |
Selection StrategyFor heavy-duty scenarios such as automotive pressing/air conditioning assembly, double-deck speed chains are preferred; standardised production lines such as bearing processing are suitable for ring speed chains.
VI. Outlook for future development trends
As Industry 4.0 deepens, the upper and lower circular double-layer multiplier chain is undergoing a triple evolution:
- Intelligent Integration: PLC system incorporates IoT sensors to monitor chain deformation and roller wear in real time to anticipate faults.
- Mixed material applications: Carbon fibre rollers with ceramic guides tested with the goal of reducing energy consumption by 301 TP3T and extending life.
- Modular ArchitectureQuick release stop mechanism with interchangeable support platforms to support line reconfiguration within 48 hours.
Exclusive views: its value is not only as an efficiency tool, butspace reconstructor--Through the vertical dimension to release productivity, for "flexible manufacturing" to provide the underlying physical support, the future or with the three-dimensional warehouse to form a deep linkage.
Self-questioning: a breakdown of the core issues
Q1: Why do electronics factories prefer double-layer to ring doubler chains?
A: Double-layer structure throughInstant return of lower blanksIt is suitable for short cycle time processes such as mobile phone assembly, avoiding the accumulation of tooling boards due to process blocking in the ring body.
Q2: How to solve the problem of chain deformation caused by heavy pressure?
A: Patented bearing platform and force reducing support column design, the press downward pressure will beTransfer to freestanding steel structuresThe chain only carries out the conveying function, increasing the life expectancy by 3 times.
Q3: Is it suitable for the food processing industry?
A: Customised full stainless steel chain plates with anti-static rollers are available, but belt conveyor lines are cheaper in light load scenarios and are recommended for sub-links such as box transfer.
Q4: Are maintenance costs significantly higher than single-tier systems?
A: Double-chain synchronous calibration requires professional equipment, but the new self-lubricating engineering plastic roller makes the maintenance cycle extended to 8000 hours, the comprehensive cost can be controlled.
