English (UK) 
简体中文 Physical principles: engineering codes for velocity superposition
The core value of Jiaxing double-deck speed chain line comes fromPrecise diameter ratio design of rollers and rollers. When the chain is running at the base speed V₁, the actual speed V of the work plate is superimposed by two parts:
- Overall chain travelling speed V₁.;
- Additional linear velocity V₂ generated by the rotation of the rollers(V₂ = (D/d) × V₁, D is the roller diameter, d is the roller diameter).
The final velocity equation is:
V = V₁ × (1 + D/d)
When D/d=2, the speed of the work plate can be up to 3 times the speed of the chain, achieving aBalance between high conveying efficiency and low wear. However, in practice, due to friction loss, the speed increase effect is usually only 85%-90% of the theoretical value, which needs to be compensated by high-precision manufacturing (tolerance ±0.1mm) and self-lubricating rollers.
Design Essentials: four-dimensional customised framework
1. Space and structural optimisation
| parameters | Standard range/configuration | Jiaxing Customisation Advantage |
|---|---|---|
| Wire Size | W250-900mm x H500-1000mm | Compact layout with increased plant utilisation 40% |
| Line length | Single-stage drive 30-40m | Modular segmentation to reduce the risk of splicing distortion |
| load capacity | 200-2000kg | Carbon steel chain reinforced for heavy loads up to 800kg |
| Balancing lightweight with durabilityAluminium profile rail (118 x 100mm) with engineering plastic chain (light duty) or carbon steel chain (heavy duty), suitable for electronic assembly and automotive parts. |
2. Electrical and power systems
- electrified transport: Conductive wheels embedded in the wire + work plate conductive rows, support for electrified work;
- Three speeds: Inverter motor (1.1kW) drive, speed range 2-20m/min, accuracy ±0.1m/s;
- Safety Redundancy: Emergency stop button + overload protection in accordance with ISO 13850 safety standards.
Industry adaptation: from electronics to heavy-duty solutions
- Precision electronic assembly::
- ±0.5mm pneumatic stopper + anti-static work plate to eliminate patch shift;
- Engineering plastic chain noise <60dB, suitable for clean room.
- Car Heavy Duty Scenarios::
- Hydraulic buffer absorbs 70% impact kinetic energy and carbon steel chain withstands 800kg load;
- The wider design of the work plate prevents deformation of the body mount.
- Food & Pharmaceutical Aseptic Line::
- Fully enclosed stainless steel frame + CIP cleaning nozzle, GMP certified;
- Self-lubricating ceramic bearings, eliminating lubrication contamination.
Smart Upgrade: A Data-Driven Leap in Performance
The limitations of traditional multiplier chains areFunctional curingtogether withdata siloThe Jiaxing programme breaks through three levels:
- dynamic control layer::
- PLC programming three-speed regulation (0.3m/s start → 1.0m/s run → 1.5m/s return), adapted to multi-process beat;
- RFID commands 90° bend diversion to reduce manual sorting 30% time consuming.
- Predictive maintenance layer::
- Vibration sensors monitor bearings >5kHz spectrum for 2 weeks advance warning of wear.
- system integration layer::
- The workstation is equipped with multifunctional sockets (power/air/network) as standard, supporting the robotic arm to be plug-and-play.
personal viewpoint: The Smart Module accounts for only 151 TP3T of the entire line cost, but reduces O&M costs by 301 TP3T -For SMEs, intelligence is not a luxury but a necessity for survival.
Implementation assurance: full life-cycle management
- Thermal Expansion Prevention and Control::
- Aluminium profile rails with 2.3mm expansion joints per metre (ΔT=30°C) are embedded in the temperature compensation algorithm;
- Compatibility Design::
- Compulsory adoption of ISO 19731 interface standard to avoid 25.4mm and 38.1mm pitch chain spares being mutually exclusive;
- Maintenance Efficiency Improvement::
- Modular quick release covers replace 20-bolt construction, compressing maintenance time from 4 hours to 15 minutes.
Future trends: maglev and decarbonisation
- Zero Friction Revolution: Suzhou Laboratory Maglev Doubling Chain reduces energy consumption by 52% and eliminates physical contact wear;
- bio-based material: Bio Nylon Rollers have a lower carbon footprint than metal 80% and are temperature resistant up to 150°C;
- distributed control: Blockchain technology enables AGVs to collaborate with shifters with a response latency of <50ms.
Self-questioning: Cracking the landing doubts
Q: Why does customisation cost 30% more than standard line?
A: The triple premium stems fromLocalisation Adaptation::
- The cost of infinitely variable speed motor + gearbox is 2 times that of a normal motor;
- The 14-station air circuit system (oil/water separator + air separation) accounts for 151 TP3T of material costs;
- Anti-static PVC work board + acrylic process signage to enhance ergonomics.
Q: Can an existing single tier line be converted to a double tier?
A: Two hard indicators need to be met:
- Plant net height ≥4 metres(Minimum space for lower refugia);
- Drive power redundancy ≥ 30%(Compensates for lift energy consumption of the lift).
Industry data shows that in 2025 Jiaxing customised multiplier chain ofSmart penetration has exceeded 65%but (not)Maglev + bio-based materialsThe technology mix will reduce production line carbon emissions by a further 40% - customisation is no longer a cost drain, but a strategic entry point for technology iteration.
