Customisation of double-decker chain lines: from demand matching to intelligent upgrading

## I. Spatial revolution in three-dimensional conveying architecture
Double-double speed chain line passes throughVertical circulation designReversed the traditional production line layout:

双层倍速链线定制

  • ​upper transport layer: Carrying of pallets for assembly tasks, with station spacing compressed to 2.5 metres.
  • ​Lower Return Channel: Dedicated toEmpty pallets return without interferenceReduction of 40% ineffective trips
  • ​Jacking and panning systemsCylinder drive + dual-guide structure to achieve cross-layer transfer of tooling boards, repeatability of positioning accuracy ± 0.1mm

This design allows the density of workstations in the same area of the plant to increase by 30%-50%. Taking the Great Wall Motor's instrument panel production line as an example, by adopting Guangliang's customised double-layer doubling chain, the number of workstations has increased by 25% while the footprint has been reduced by 37.5%, and the annual production capacity has been increased to 180,000 units.

## II. The five key stages of the full customisation process

Stage 1: Precise targeting of demand

​Scenario-based requirements analysisNeeds attention:

双层倍速链线定制

  • ​Load Characteristics: Automotive components need to carry heavy loads of over 2 tonnes (hardened alloy steel chains), while 3C electronics are usually ≤500kg (engineering nylon chains).
  • ​environmental adaptation: Pharmaceutical industry requires 316L stainless steel material resistant to alcohol disinfection, electronic workshop needs anti-static design (resistance ≤ 10⁶Ω)
  • ​Functionality ExpansionPre-built RFID interfaces, robot docking coordinates, and other future upgrade requirements.

​Lessons from casesA lithium battery factory did not reserve the AGV connection port, and the cost of later transformation exceeded the initial investment by 30%.

Stage 2: Modular design in practice

Image Code
graph LR
A[Layout planning] --> B{Space limitations?}
B --Height of plant<5m--> C[Compact double-decker layout]
B --- Plane Sufficiency --> D[Single-layer ring programme]
C --> E[Drive system selection]
D --> E
E -- overloaded scene --> F[3x speed chain + 5kW dual motor drive]
E -- light duty high speed --> G[2.5x speed chain + servo inverter]
F --> H[Control system]
G --> H
H -- Basic Functions --> I[PLC + touch screen]
H -- Smart Factory --> J[Integrated MES + IoT module]


(Source: Kouryuu Intelligence 2025 Customised Case Bank)


Stage 3: Hard standards for manufacturing and validation


    

  • ​Core component processingSprocket tooth shape processing up to IT7 level accuracy, guideway straightness error ≤1mm/m.
    • 

  • ​load test: 72 hours of continuous full load operation, record motor temperature rise (ΔT≤15℃), chain elongation (≤0.3%)
    • 

  • ​error-proof designSafety light curtain + emergency stop dual circuit control, response time <0.5 seconds
    • 



​Industry pain point breakthrough: Solve the runout problem of long-distance conveying (>40m) by laser alignment gauge calibration, so that the failure rate is reduced by 60%




## III. The Golden Rule of Selection Decisions


Rule 1: The formula for matching materials to loads






take
Preferred option
Guide to avoiding the pit






Vehicle/heavy labour (>1 tonne)
All-steel chain + hardened rollers
Avoid the use of 3 times the speed of the chain, overload 30% when the risk of chain breakage increased 50%




Electronics/appliances (≤500kg)
Engineering plastic chain + self-lubricating bearing
Humidity >70% environment requires anti-static coating




Food/Pharmaceuticals
316L stainless steel + sealing cover
Grease needs to be FDA compliant






Law 2: The Art of Balancing Speed and Precision


    

  • ​Precision Assembly Scene: AdoptionServo Closed Loop ControlS-type acceleration and deceleration curves (acceleration ≤ 0.5m/s²)
    • 

  • ​High-speed sorting scene: 2.5x speed chain + inverter motor, speed range 5-15m/min
    • 

  • ​Accumulation function keyThe gap of the stopper is strictly controlled at 0.1-0.3mm, too tight leads to the failure of speed doubling, too loose triggers the positioning of the super poor.
    • 





​real time data: A mobile phone patch line reduces offset rate from 1.2% to 0.05% through servo positioning modification.




Law 3: Cost and delivery time game strategy


    

  • ​Standardised modules: Reduced lead time to 15 days by selecting common parts such as aluminium profile guide rails (118 * 100 size).
    • 

  • ​Cost optimisation points: Drive unit accounted for 35% of the total cost, domestic high-quality motors (such as Yaskawa) can replace imported brands
    • 

  • ​Early warning of hidden costsNeglect of self-lubricating design will lead to an increase in annual maintenance costs of ¥80,000/km.
    • 





## IV. Three major evolutionary directions for intelligent upgrading


    

  1. 

    ​digital twin (DT) monitoring​
    
Embedded in rollersMicrostrain SensorsReal-time monitoring of chain tension fluctuations, early warning of overload risk (error rate <5%)
    

    2. 

  2. 

    ​Hybrid Drive Architecture​
    
Base conveyor with conventional motor and integrated jacking mechanismLinear motorsPositioning accuracy jumps to micron level
    

    3. 

  3. 

    ​Adaptive Speed Ratio​
    
Development of a variable-size roller structure, hydraulically adjustableOnline Speed Switching(2.5X ↔ 3X), with a reduction in changeover time of 80%
    

    4. 





​personal prediction:: 30% high-end production line will adopt "IoT+hybrid drive" architecture by 2027, with virtual commissioning technology enabling compressed production cycle time 40%






## Self-questioning: customised core doubts cracked




​Q1: How long is the customisation cycle usually? Which parts of the process are the most time-consuming?​

A: Routine projects require45-60 days, the key time-consuming point in:




    

  1. Programme validation (7-10 days): as a result of repeated changes in customer requirements
    2. 

  2. Machining (15 days): 601 TP3T man-hours for sprocket tooth profile finishing
    3. 

  3. Intermodal testing (10 days): modular pre-assembly is recommended to shorten this phase
    4. 





​Q2: Why is it prudent to use 3x chaining for heavy load scenarios?​

A: 3x chain ofLarger roller-roller diameter ratioThe stress is concentrated at the hinge point of the chain plate when overloading. Measured data show that when the load exceeds the standard 30%, the risk of chain breakage of 3xspeed chain is 50% higher than that of 2.5xspeed chain.






​Q3: How to reduce long-term maintenance costs?​

A: Implementation of the "three defences and one intelligence" strategy:




    

  • ​dust: 3 times longer life in dusty environments with the addition of a sealing cover.
    • 

  • ​anti-wear: Monthly inspection of roller-roller clearance (>0.1mm)
    • 

  • ​rust prevention: Lithium-based water-resistant grease for wet environments (100°C viscosity ≥46mm²/s)
    • 

  • ​Intelligent Early Warning: IoT platform pushes bearing temperature rise anomalies in real time
    • 





​Q4: Does modular design really reduce costs?​

A.Increase 10% inputs in the short term and reduce 30% costs in the long term-Modularity makes the new workstation transformation cost <￥30,000, and reduce downtime to 8 hours.

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