English (UK) 
简体中文 Hey, is your workshop as crowded as the morning rush hour underground? The assembly line takes up space, not to mention the empty pallets have to find someone to move back? Do not worry! These industrialists in Wuxi have figured it out long ago--Double Speed ChainIs a special cure for small space, low efficiency "special medicine"! Today, we will break open the crumbs to talk about, this thing in Wuxi factory how to play flowers, especially to the new industry is still blindfolded you point a clear way!
I. What is a double-deck speed chain? "Space folding" in the workshop.
Simply put, it's aCircular runway with two levels::
- Upper run full of material: Tooling boards carry parts whirring as workers assemble them along the line;
- "Sneaky" returns from the lower levels: The exhausted empty board swishes down to the lower level and slips quietly back to its starting point;
- The core organ is the plate return machine.: By cylinder jacking + chain drive, automatic flap, save the trouble of manual moving.
Guess what? For the same amount of production.Nearly half of the area was cut off directly! Wuxi electronics factories, air-conditioning assembly line (such as a factory computer mainframe line) crowded to turn the place, this move is a lifesaver.
What makes it "twice as fast"? The secret is in the chain!
The name doesn't blow! The chain climbs slowly, but the work plate can race up to chain speed of the2.5 to 3 times(Depending on whether you use a triple or a double chain). How do you do it? Hey, here comes the formula (don't panic, just speak human):
v = (1 + D/d) × v₀
- D is the roller diameter(math.) genusd is the roller diameter--The big roller turns with the small roller, and the work plate naturally scurries fast;
- In practice, it also depends onAluminium profile railWear-resistant and noise-reducing.Variable frequency motorsAdjustable speed (2-20 metres/minute at will).
Results?Chain wear is low, but parts on the plate "fly" around, the overall efficiency rubbed off!
Wuxi real-world cases: electronic factories, automobile factories how to rely on it to turn around?
▍ 案例1：创沃思拓给电子厂搞的“带电狂奔”方案
- sore point: Inspection processes are jammed and assembly lines are blocked into car parks;
- solution (a math problem): Tooling boards plusConductive wheel + carbon brush, side-transmission power-up detection;
- effect: Saves 3 inspection stations and troubleshoots 40% faster.
▍ 案例2：三锐科技在空调装配线的双层魔法
| comparison term | single layer cable | Double Speed Chain |
|---|---|---|
| take up space | 100m2 | 60m2↓40% |
| a porter | 2 people | 0 people |
| payback period | 18 months | 8 months |
| (Data from line modification reports) |
▍ 汽车厂同步难题破解
There was a factory where the upper and lower levels were always "fighting", and the proposal given by Kouryuu was absolutely impossible:
- mechanical synchronisationTwo motors.Single motor + double output reducerThe speed is pinched to death;
- electronic positioning:: AddRFID chipThe work boards go everywhere.
Results?Efficiency increased by 40% and failure rate dropped by 65%.-This input, worth it!
Fourth, the newbie must pit guide: you ask and I answer!
Q: What can I do if the upper and lower speeds don't match up? Urgent!
A: A case-by-case treatment!
- Structural differences: First check the chain pitch, roller size is not uniform, wear parts hurry to change;
- Electrical asynchrony: PLC plusEncoder FeedbackThe motor speed is fine-tuned in real time;
- functional conflict(e.g., upper level to be sorted, lower level to be cached): use thePartition Control StrategyThey're not going to interfere with each other!
Q: They say repairs are hard, what's so hard about them?
A: Three major "flashpoints"!
- Blocking cylinder jammed--Dusty workshops are cleared once a week;
- Chain deflection--The rails must be levelled during installation;
- Lifting and extracting air from plate return machine--Slide sliders need to be replaced if they are of poor quality.
lit. password for avoiding a pit (idiom); to avoid a pitfall by avoiding words: The contract states training services + deadening of operating norms + stocking up on spare parts (blocker rollers, seals)!
Q: To choose aluminium or steel structure? I've got cancer!
A: Getting to the core -Depends on how heavy your load is.!
- Aluminium profiles: light, rust-proof, assembled like Lego-≤150kgThe TVs and small appliances are selected with closed eyes;
- carbon steel: Dead heavy but easy to build - suitable for engines, motors and other "iron bumps", at the cost of noise + painting to prevent rust.
Editor's Clap:
Space is money, efficiency is life! Wuxi factory to double speed chain to play into the "space money printing machine", relying on not brute force, is theUnderstanding the needs + precise design. Newbies don't just stare at equipment quotes, count the plant rent saved, the labour costs cut - theEvery penny that's more expensive is doubled back to you on the assembly line.. Remember, good equipment doesn't save money, but the cost and profit saved will wake you up in the middle of the night laughing sooner or later!
