Customised double-deck speed chain: a manufacturing revolution in space efficiency and flexible adaptation

Driven by the combination of escalating industrial land costs and surging demand for flexible manufacturing, theCustomised double-layer speed chain systemThrough non-standard design and modular architecture, the company has successfully cracked the dichotomy of "high beat production" and "limited space", which has increased the ping efficiency of the automotive battery production line by 3 times, and the pass rate of pharmaceutical filling is close to 99.971%. TP3T has become the invisible efficiency engine of advanced manufacturing.

🔧 The core contradiction of customised needs

​The Paradox of Space Constraints and Efficiency Improvementsis the origin of customised design. The standard doubler chain will meet 80% requirements in electronics shops, but when it comes to conveying 280kg battery packs or Class 10 clean environments.Non-standard customisation has become a necessityTake Great Wall Motor's instrument panel assembly line as an example. Take Great Wall Motor's instrument panel assembly line as an example, through the wider design of the work plate (width increased to 1.2 metres) and embedded electronic screen, the carrying capacity is increased by 40% while real-time monitoring of process parameters is realised.

​Industry Differentiation Pain Points::

• ​Pharmaceutical aseptic production line: Need to isolate upper and lower airflow, customised negative pressure ducting to prevent cross contamination
• ​Semiconductor workshop: Silicon Nitride Ceramic Roller Replaces Metal, Eliminates Risk of Particle Contamination
• ​Lithium assembly: Six-axis levelling jacking mechanism to compensate for pack deformation (accuracy ±0.05°)

​personal experience: Customisation is not a stack of features, butReplacing Compromise with Engineering Intelligence. Uncalculated thermal expansion in a Shenzhen electronics factory led to an average of 12 failures per month, while customised thermal compensation joints resulted in zero failures - this is exactly how precise customisation quantifies value.

⚙️ Key technical elements of engineering customisation

​1. Modular architectural design​
The essence of customisation isReconfigurable Module Portfolio. Core modules include:

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① Conveyor layer module: replaceable 2.5x/3x speed chain
② Lifting mechanism: magnetic floating type (reorganisation time 40 minutes) or pneumatic type.
③Control interface: standardised electrical slot to support PLC/MES system plug and play.  
​case (law): Tenneco's battery line has extended its life from 3 to 7 years by replacing acid-etch resistant modules, reducing maintenance costs by 60%.
​2. Material selection game theory​



take
Traditional programmes
Customised optimisation solutions
Benefits Comparison




food processing line
304 stainless steel
Titanium alloy coated chain plate
Salt spray resistance↑300%


High vibration environments
Carbon Steel Roller
Carbon fibre reinforced PEEK
Weight loss 50%, amplitude ↓70%


wet room
All chain galvanised
Ceramic coating of critical areas
Cost down 45%, life expectancy flat



​3. Speed control algorithms​

Customisation needsDynamic matching of process beats::

Conveying section: 2.5 times speed (18m/min)
50cm before entering the work station: switching single speed (7.2m/min)
Positioning segment: 0.5x speed (3.6m/min)


Actual measurements at the German factory show that this strategy reduces positioning time by 41%, with an overshoot of ≤0.15mm.


🏭 Explanation of customised solutions for vertical industries
​Heavy-duty conveying of automotive components​

tooling boardEmbedded Pressure SensorsReal-time monitoring of 280kg battery pack deformation, data linkage jacking mechanism automatically levelling. After the application in a battery factory, the defective rate of the product was reduced from 1.2% to 0.3%, meanwhile, the number of manual inspection posts was reduced by 5 people.
​Microelectronic assembly​

Antistatic chain (surface resistance 10⁶-10⁹Ω) fitsGold Contact Conductive WheelThe production line is designed to eliminate electrostatic breakdown during precision IC mounting. As a result, Suzhou Optical Module Production Line has suppressed the scrap rate from 0.8% to 0.12%.
​Pharmaceutical aseptic filling​

Customised 3D airflow simulationlaminar flow barrier::

Upper level: Class A laminar flow covered filling station
Lower level: independent negative pressure air ducts to isolate the empty board backflow

Biological products filling pass rate increased to 99.97%, breaking through the bottleneck in the industry.


🤖 Intelligent Systems Convergence Evolution
​Digital twin pre-maintenance system​

Previewing faults in a virtual model:

Automatic lubrication command triggered when coefficient of friction reaches 0.15
Instant alarm for chain tension deviation >10%

An LCD panel plant took this opportunity to reduce average annual downtime from 86 hours to 7 hours.

​Flexible Reconfiguration Technology​

​Programmable links: RFID chip implanted in the chain plate, autonomous routing of the workpiece to the designated workstation.
​Maglev jacking machine: Elimination of mechanical guides and reduction of reorganisation time from 6 hours to 40 minutes

Model switching time is reduced by 73% in automotive mixed-line production.


🧭 Customised implementation pathway map
​1. In-depth diagnosis of needs​

Mapping of shop floor heat maps: locating temperature/vibration/humidity peak areas
Load spectrum analysis: recording of peak loads, frequency of shocks (e.g. at the moment of pack drop)

​2. Modular selection sandbox​
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①Base frame: Aluminium profile rail (118×100mm) or steel reinforced frame
② Power unit: variable frequency motor (conventional) vs servo motor (precision positioning)
③ Expansion interface: reserved AGV docking track / robotic arm mounting base  
​3. Simulation of line dynamics​

SolidWorks motion simulation verification:

Dynamic matching of jacking cylinder stroke to sprocket backlash
Thermal deformation compensation programme for ambient temperature difference ±5°C (30m line expansion 2.1mm)


​Exclusive dataChangzhou Guangliang's customised production line has a payback cycle of <14 months - 35% efficiency gain in the battery line + 2.3% yield improvement in the pharmaceutical company, and the customised cost is usually recovered within 1.5 years.


Ask Yourself: Three Questions for the Customised Core
​Q: Are customisation lead times and costs much higher than standard equipment?​

Answer.Deep customisation increases the cost of the 30% but improves the energy efficiency of the 80%.. Take the VinFast motor cable for example: the 16m non-standard cable customisation cycle time is 45 days, which is 50% longer than the standard cable, but the failure rate drops by 70%, and the combined ROI cycle time is still shortened to 16 months.

​Q: How do you balance versatility with industry customisation?​

Answer.Adoption of "Base Module + Industry Suite" architecture::


Basic module (60% of cost): standardised guide rails/drive units
Industry Kits (40% of cost): Semiconductor anti-static modules/pharmaceutical sterile barriers, etc.

Cross-industry reuse is still up to 70%.


​Q: Does customised equipment make it more difficult to operate and maintain?​

Answer.Intelligent Diagnostic System Anti-Degradation Operations Complexity::

AR-assisted Repair: 3D perspective location of fault points (false judgement rate ↓90%)

Instead, a power plant's O&M timeframe was reduced from four hours to 35 minutes.