Hefei double-deck speed chain conveyor line: engineering breakthroughs in space efficiency and intelligent manufacturing

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Upper conveyor line → Workpiece plate loads for complete assembly/inspection → Finished product off the line
↓ Pneumatic or magnetic levitation jacking machine (layer transition)
Lower level return line → empty pallets return to starting point → space utilisation increased 60%[3,5](@ref)
This design compresses the flat occupancy by more than 40%, while using gravity-assisted reflux to reduce energy consumption by 17%, which is especially suitable for the Hefei Industrial Park where land costs are high.
​Doubling MechanismdependenciesRoller-roller composite structureThe precision fit of the

​Internal chain roller(diameter d) in contact with the guideway, providing a base velocity V₁
​External Chain Roller(Diameter D) carrying the workpiece, the difference in diameters generates an additional velocity V₂
​Growth rate formula: Vₜ = V₁ × (1 + D/d)

When D/d=1.5 (e.g. roller 20mm + roller 30mm), the speed of the work plate can be up to 2.5 times of the speed of the chain, and the conveying efficiency is upgraded by 40% compared with the traditional equipment.


​personal experience: The Hefei enterprise innovatively combinesDiameter ratio adjustmenttogether withPitch optimisationCombined with the adjustable parameter design (1.5~3 times speed) to meet the needs of automotive, electronics and other industries with differentiated beats, avoiding the cost waste caused by "over-design".


​Technology moat for Hefei companies​
​Modular Engineering ArchitectureIt is the core competence of local manufacturers. Both Hefei Jieming and Tengri Industrial use the"Standardisation of basic modules + customisation of industry kits"Mode:

​basic module(60% of cost): Scale down cost of general-purpose components such as aluminium profile guide rails (118×100mm) and inverter motor drive units
​Industry Kits(Accounting for the cost of 40%):

Semiconductor workshop: Silicon Nitride ceramic rollers (anti-particle contamination)
Pharmaceutical aseptic line: negative pressure air duct isolation layer (to prevent cross-contamination)
Lithium battery assembly: six-axis levelling jacking mechanism (load capacity 280kg±0.05°)

This architecture enables cross-industry reuse of up to 701 TP3T, with customised cost increases contained within 301 TP3T.



​Intelligent Control System Evolution::

​Dynamic stopping technologyLaser sensor + servo stopper to achieve ±0.1mm positioning accuracy, an optical module production line in Suzhou, scrap rate from 0.8% to 0.12%
​digital twin operations and maintenance (DTOM): The virtual model previews the alarm triggered when the chain tension deviation is >10%, and the average annual downtime of a panel plant is compressed from 86 hours to 7 hours.


​In-depth analysis of vertical industry applications​
​New Energy Vehicle Battery Pack Assembly(Hefei Key Industries)

​sore point: Poor contact due to pack deformation
​Hefei Programme::

Embedded thin-film pressure sensors in tooling boards for real-time deformation monitoring
Dynamic levelling of the data-linked maglev jacking mechanism
Result: Defective rate decreased from 1.2% to 0.3%, 5 inspection posts were reduced, and the production line ping efficiency increased to 3.4kWh/㎡.



​Pharmaceutical aseptic filling line​

​innovative design::

Upper filling area: Class A laminar flow coverage (ISO Class 5 standard)
Lower empty board backflow: independent negative pressure air duct isolation
Result: 99.97% pass rate for biological products filling, breaking through the bottleneck in the industry.



​3C Electronic High Density Assembly​


Anti-static chain (surface resistance 10⁶-10⁹Ω) with gold contact conductive wheels
RFID chain link realises autonomous routing of workpiece boards and shortens the switching time of mixed-line production by 73%.


​Exclusive insights: the balancing act of cost and innovation​
​Whole Life Cost Revolution::

​Lubrication InnovationPTFE food grade grease extends maintenance intervals from 2 weeks to 3 months, reducing maintenance costs by 60%
​topological optimisationNon-load-bearing area hollowing weight reduction of 40% (such as the middle of the chain plate openings), plant load-bearing transformation cost savings of 2.9 million yuan / production line.

​Cognitive upgrading of safety design::

A factory in Hefei had over-reliance on electrical interlocks (guard door signal linkage suspension) and failed to set hard limits on cylinder travel, resulting in the jacking mechanism crashing into the guide rail after the interlock failed.Mechanical redundancy is the ultimate line of defence.-Suggests synchronisation with physical block + sensor double insurance, failure rate can be reduced by another 50%.


​Self-questioning: three questions for engineering landing​
​Q: How do I root out upper and lower speed desynchronisation?​

Answer.Mechanical synchronisation as a foundation, electrical compensation as a supplement::

Priority is given to single-motor coaxial drives (e.g. dual output gearboxes) to physically eliminate speed deviations;
Encoder feedback + PLC dynamic speed regulation is required for split drive (accuracy ±0.1mm).


​Q: Do I need all stainless steel chains for pharmaceutical lines?​

Answer.Localised reinforcement is better than global stackingTitanium alloy coated chain plates are used only in highly corrosive sections such as the filling area, while carbon steel + ceramic coating is used in other areas, resulting in a cost reduction of 45% and equal life time.

​Q: Does modularity sacrifice stability?​

Answer.Interface accuracy determines reliability::

Guideway splicing surface pre-set positioning pins (tolerance ±0.05mm);
The electrical slots are waterproof to IP67;

The restructuring failure rate inversely decreased by 50% after application in one power plant.