Multiplier chain speed increase principle explained: roller and roller speed mystery

Scenario-based problem introduction

On the assembly line of an electronics factory, workers found that the speed of workpiece movement on the conveyor belt was insufficient, resulting in production capacity stuck at 200 pieces per hour that could not be increased. Engineer Wang was asked to increase the conveyor speed to its original level without replacing the motors.2.5 times. The solution he proposes is.Replacement of normal conveyor chains with speed multiplier chains. How does this modification lead to a leap in speed? The central secret is hidden in the difference in diameter between the rollers and the rollers.

I. Speed superposition: the "gear effect" of rollers and rollers

The nature of the multiplier chain's growth rate ismotion overlay(Figure 2):

1. ​base speed: The roller (diameter d) rolls purely on the guideway, driving the chain with speed ν₀;
2. ​additional speed: The rollers (diameter D) are rigidly connected to the rollers, and since D>d, the roller edges have a higher linear velocity (Eq.Additional velocity = (D/d) × ν₀);
3. ​Total velocity synthesis: Tooling board speedν = ν₀ + (D/d) × ν₀ = ν₀ × (1 + D/d).

✅Scenario Validation: Xiao Wang chooses 3 times speed chain (D/d=2), when the chain speed ν₀=2m/min, the speed of the workpiece plate is up to6m/minThe efficiency is increased by 3 times.

II. Structural design: precise control of the diameter ratio D/d

The growth rate effect is directly dependent onDiameter ratio of roller to roller, but the design needs to balance physical constraints:

⚠️Friction loss correction: The actual speed increase is about 90% of the theoretical value due to guide friction and sliding (e.g., actual ν ≈ 2.7ν₀ for a 3-fold chain).

III. Engineering practice: how to select and optimise

Little King has three scenarios to address in his remodelling:

1. ​Growth rate than choice::
   • Light load scenario (<500kg) → optionEngineering Plastic Rollerof 2.5x speed chain (low cost and low noise);
   • Heavy load scenario (>1000kg) → SelectionSteel Rollerof 3x speed chain (D/d=2, load up to 3.92kN).
2. ​Non-slip differential design::
   • Retention between the work plate and the rollersfrictional slipThe following is an example of how this can be achieved in conjunction with a stopper.Precision parking(e.g. cylinder block stops) to meet assembly beat requirements.
3. ​Efficiency bottleneck breakthrough::
   • For long working hours stations (e.g. welding), additionalJacking and lifting mechanismThe workpiece is moved out of the main line operation to avoid blocking the subsequent conveyor.

IV. Industry Applications: Real Cases of Efficiency Improvement

Comparison of the effect of a retrofit on an air conditioning assembly line:

💡core value: Chains run at low speed (to reduce wear and tear), and work plates move at high speed (to increase efficiency), to achieve"Low speed drives high speed."The energy saving effect of the

Conclusion: The "Speed Code" of the Speed Chain

The diameter ratio of roller to roller (D/d) is the multiplier chain'sphysical leverBy precisely controlling this ratio, engineers can customise conveyor speeds as if they were "adjusting gears". By precisely controlling this ratio, engineers can customise conveyor speeds as if they were "adjusting gears". Think back to when you were on an automated production line and saw a pallet slide by at speed.Smaller rollers drive larger ones, and the difference in diameter becomes a wing of efficiency..

References: multiplier chain structure diagram, growth rate formula derivation, table of load parameters.