English (UK) 
简体中文 Hey, is that doubler chain in your shop always acting up? The plates run fast and slow, and the rollers crack in less than half a year?It's probably because the roller ratio isn't right.I'm going to talk about it! Let's talk about it today - how can the size of the rollers of the doubler chain work together to make the production line soar?
First, what makes the chain of times the speed "times the speed"? Maths teacher can not understand the mystery
To put it bluntly, it relies onDifferences in roller diameters play a speed trick! Ordinary chains climb 1 metre, work plates can soar 3 metres! The secret is all in the formula:
- rollers(Diameter d) stuck on the guide rail slow rolling
- high roller(Diameter D) holds the work plate in a frantic rotation
👉Speed Magic Formula: Plate speed = Chain speed × (D/d + 1)
Take a chestnut 🌰:
- Small roller diameter d=12mm
- Large roller diameter D=18mm
- Chain speed v = 10 m/min
👉 Tooling plate speed = 10 × (18/12 + 1) = 10 × 2.5 =25m/min! Direct 2.5x takeoff!
Guess what? An air-conditioning plant measured: adjust the ratio to D/d = 1.67 (small roller 15mm + large roller 25mm).Daily production capacity from 800 units to 2000 units! Workers no longer need to run after the assembly line.
Second, the ratio design life and death line! Three big pits newbies must fall into
Don't think you can just stuff two rollers in and multiply your speed! One wrong step in these three places and the whole thing falls apart:
Pit ① Proportionality
- Golden ratio D/d ≈ 1.5(2.5x chain) orD/d≈2.0(3x chain)
- Messing around with say D/d=1.2? The actual growth rate is only 1.8 times! The assembly line will turn into a tortoise speed.
Pit ② Insertion depth messed up
tumblerInserted into the large roller hole(Figure 3 structure):
- Optimum depth = small roller length ×0.3 to 0.5 times
- Shallow insertion → transmission slippage | Deep insertion → friction increases dramatically
Pit ③ Material hard to touch
| take | Small roller material | Large roller material | Rollover warning |
|---|---|---|---|
| Electronics factory (light duty) | engineering plastics | engineering plastics | Must be melted above 80°C! |
| Automobile factory (heavy duty) | steel (bar, screw, product etc) | steel (bar, screw, product etc) | No lubrication? It'll be rusted to death in three months! |
📢A case of blood and tears: A factory in Zhongshan used plastic rollers with D/d=1.8 to send engines - the small rollers broke under heavy pressure.The work plate overturned and smashed 20 gearboxes!
Third, the actual scale table! Copy it to save $30,000 in repairs
Running around the factory floor, I pulled outFour mainstream specifications(Data synthesis web page 6 and web page 9):
| hyphen | Pitch (mm) | Small roller diameter (mm) | Large roller diameter (mm) | D/d ratio | Real growth rate |
|---|---|---|---|---|---|
| BS25-C206B | 19.05 | 11.91 | 18.3 | 1.54 | 2.3 times |
| BS25-C208A | 25.40 | 15.88 | 24.6 | 1.55 | 2.3 times |
| BS30 | 38.10 | 22.23 | 36.6 | 1.65 | 2.7 times |
| Heavy duty customised models | 50.80 | 28.58 | 48.0 | 1.68 | 2.7 times |
👉storm theory (math.): Small and medium-sized factories close their eyes and chooseBS25-C208AD/d=1.55 is the best value for money, messing around chasing 3x speeds is pure burn!
Why does the ratio of four to one still fall off? Hidden parameters kill people
The teacher taps his thigh and warns: don't just stare at the ratio! These three parameters are the true ancestors:
① Gaps are fatal
- Small Roller & Socket Clearance<0.1mm(Vernier calipers!)
- Over 0.3mm? bam like iron on the drive!
② Straightness is an invisible killer
- Straightness error per metre of guideway≤0.5mm(Laser calibration!)
- Chain jumps over 1mm and gets stuck.
③ Temperature expansion coefficient
- Plastic roller workshop super60°CThe D/d ratio is automatically +0.1!
- Run fast in summer and slow in winter? Hurry up and change the steel rollers!
Fifth, the theory of future violence: the chain without this design in 2026 is scrap metal!
After ten years in the industrial world, I see three deadlines:
- Smart rollers will be on top::
Roller InsertsPressure sensors, overloaded with automatic speed reduction (now breaks before stopping!) - Variable Scale Black Technology::
Hydraulically adjustable D/d ratio, one chain compatible with 2.5x and 3x speeds - Lubrication-free composites::
Graphene-coated rollers that don't need refuelling for life!
Wait and see: a laboratory in Songshan Lake is already testing D/d=2.2.4x Chain(Page 9 spoiler) - it's the cost that scares the shit out of me, a metre is enough to buy a Wuling Honda!
I'm going to throw in a final punch line.
Don't be fooled by the sales pitch that "bigger is better"! Do the financial maths:
| sports event | D/d = 1.5 (2.5x speed) | D/d = 2.0 (3x speed) | disparities |
|---|---|---|---|
| procurement price | reference price | +40%↑ | Spend 40,000/50 metres more |
| Repair and replacement costs | Roller Universal | Customised pieces at sky-high prices | Two times more expensive |
| power consumption | Motor 7.5Kw | Motor 11Kw↑ | Burning an extra 30,000 in electricity costs per year |
Next time a supplier blows a 3x, dislike it three times outright:
"What's the actual D/d? Dare to sign a 2 year warranty? Overload 30% test video bring it!"
--Can demonstrate on the spot to deserve to charge you!
