English (UK) 
简体中文 The underlying logic and double-layer evolution of the multiplier chain
The core value of the Speed Chain is"Low-speed chains drive high-speed workpieces."of physical intelligence. Its unique structure is achieved through theDifference in diameter between roller (diameter D) and roller (diameter d)Achievement of growth rates:
- motion superposition principle (physics): The actual speed of the work plate = the speed of chain movement (V₁) + the additional speed of roller rotation (V₂ = (D/d) × V₁), i.e.Total V = V₁ × (1 + D/d).
- Adjustable speed ratio: By adjusting the D/d ratio (commonly 1.5-2x), 2.5x or 3x speed conveying is achieved to meet the beat demand in scenes such as electronics assembly.
The double-layer speed multiplier chain is upgraded on this principle to360° circulation system::
upper production layer: Conveying of workpieces on carrier plates at speeds of up to 18 m/min;
lower return layer: The unloaded workpiece is cycled back and the speed is reduced to 8 m/min to save energy;
Grabber connection: Cylinder-driven lifting mechanism to achieve the transfer of upper and lower workpiece plates, forming a closed loop.
personal viewpoint: The essence of this design is"Trading space for time."The case of an automotive plant. In the case of an automotive plant, the 12-metre high plant was deployed with a 2.3-fold increase in capacity per unit area - confirming the Industry 4.0 era!Vertical intensification is replacing flat expansion, becoming the breaking point for the land cost dilemma.
Technical architecture of the three-dimensional circulation system
The stability of a double-deck multiplier chain automatic line relies on the synergy of three major modules:
Innovations in Mechanical Structures
- Adjustable height mechanismThe elliptical wheel lifting system (Patent CN202222905222.0) realises stepless adjustment of the height of the lower floor (0.8-2.5m), which is suitable for different sizes of materials;
- Seismic heavy duty chains: Hardened alloy steel chain (tensile strength ≥1200MPa) with hydraulic damper to offset Ⅶ vibration, 200kg load deflection ≤0.5mm;
- Modular guide railsT-slot design is compatible with RFID readers and vision sensors with ±0.1mm positioning accuracy.
Electrical control centre
- PLC master controlProgrammed to co-ordinate the lifting and lowering of the transfer machine and the starting and stopping of the chain, with manual/automatic dual mode settings for commissioning and production;
- synchronisation module: Encoder feedback of the motor speed, real-time calibration of the upper and lower speed difference (e.g. synchronisation via EtherCAT bus in case of independent drives);
- safety interlock: Lowering of the loader is prohibited when the lower level is not in position to avoid collision.
Energy Efficiency Optimisation Engine
- Dynamic speed control: Reduce speed to 8 m/min for heavy loads to prevent deformation, and increase speed to 18 m/min for empty loads to improve efficiency;
- Valley power boost: Identify low-cost electricity periods and automatically speed up by 251 TP3T, reducing annual electricity costs by 181 TP3T;
- kinetic energy recovery: Schneider ATV630 inverter converts braking energy into electrical energy with a recovery rate of 23%.
The Road to Conquest for Industry Adaptation
Different scenarios need to be targeted to overcome technical bottlenecks:
Automotive Manufacturing
- Heavy Duty ChallengeSteel roller chain with a load capacity of 2000kg supports the engine conveyor; hydraulic bearing platform (patent CN219905685U) shares the 60% load to prevent deformation;
- Synchronisation of pain points: Single motor + dual output reducer drives upper and lower levels, eliminating speed deviation and increasing efficiency by 40%.
Electronic clean room
- electrostatic protection and control: Copper alloy guide rail + conductive roller combination, charge dissipation <0.1 sec;
- Dust-free design: Fully sealed guideway + self-lubricating bearings, meets ISO 14644 Class 5 standard.
Food and Pharmaceutical Industry
- Hygiene upgrade: Stainless steel chain with nickel plated finish, resistant to acid and alkali corrosion;
- Temperature adaptability: Reserve 0.2mm/m expansion joint for guide rail to eliminate thermal expansion and contraction stress.
controversial insight: Weatherproofing ≠ material stacking! A photovoltaic plant passedEnvironmental Data Prediction System(analysing chain wear in relation to temperature and humidity), automatic sealing reinforcement before the rainy season, breakdown downtime down to 4 hours/year -Intelligent pre-adaptation is more economical than simply upgrading materials.
The Triple Breakthrough of Intelligent Evolution
dynamic scheduling algorithm
- Fault Emergency Access: Lower level preset cache track, automatic diversion when sensor detects abnormality, avoiding full line downtime;
- Beat Optimisation: PLC adjusts the blocker timing in real time according to the workstation load, and the bottleneck workstation wait is shortened by 55%.
digital twin pre-control
- Virtual Load Testing: Simulation of the 300kg ultimate load-bearing capacity to pre-determine the point of deformation, and the commissioning cycle of the new line was reduced from 14 days to 5 days;
- heat map positioning: Identify high wear areas such as high altitude turning sections and increase lubrication points in advance for 2.8 times longer life.
Flexible production support
- Quick release link systemCarbon steel links + self-locking pins, replacement takes <30 minutes (4 hours traditionally);
- multiprotocol communicationReserve Profinet/EtherCAT interface, response <50ms in co-operation with AGV.
Self-questioning: the core concern of smart upgrading
Q: How to prevent chain deformation for 200kg heavy load?
A: Triple protection of material, structure and intelligence is required:
- Material Enhancement: Hardened alloy steel chain (tensile strength ≥1200MPa);
- pressure shift: Hydraulic support platform for load sharing (Patent CN219905685U);
- dynamic compensation: High temperature grease is automatically injected when the coefficient of friction > 0.15.
Q: How to solve the problem that the upper and lower levels are running out of sync?
A: Scenario-based policy:
- mechanical synchronisation: Independent motor to coaxial drive or coupling connection;
- electrical synchronisation: PLC adds encoder feedback module for real-time calibration of rotational speed difference.
Q: How can SMEs transform at low cost?
A: Phased implementation strategy:
- initial stage: Carbon steel base model (costs 35% less than stainless steel) with fixed lower height;
- mid-term: Add inverter module to realise valley power speed control, 1.5 years payback;
- at a fixed date in the future (e.g. for repayment): Deploying a digital twin reduces O&M costs by another 42%.
When a double-decker multiplier chain carrying a car's battery pack automatically speeds up in the midnight tariff valley, the fusion of metal rollers and data algorithms is reconfiguring the dimensions of manufacturing efficiency. Actual measured data from a car company reveals."Spatial capacity density" of the three-dimensional circulation system(capacity/energy ratio per unit volume) up to 3.1 times that of a traditional single-layer line - a sign that manufacturing competition has shifted from flat efficiency toData penetration wars in stereospaceIn the next ten years, the core indicator of the advanced production line may no longer be the speed of 100 metres, but the turnover precision and entropy reduction capacity of the value flow per cubic metre of space. In the next ten years, the core index for judging the advancement of the production line may no longer be the 100-metre conveying speed, but the turnover precision and entropy reduction capability of the value flow in each cubic metre of space.
