English (UK) 
简体中文 Physical Intelligence and Double-Layer Evolution in Multiplier Chains
At the heart of the multiplier chain lies"Low-speed chains drive high-speed workpieces."The mechanical philosophy of the The principle of its speed increase stems from the difference in diameter between the roller (diameter D) and the roller (diameter d):
- Motion superposition formula: Actual speed of the tooling plateTotal V = V₁ × (1 + D/d), where V₁ is the chain movement speed;
- Speed ratio control: By adjusting the D/d ratio (1.5-3x), 2.5x or 3x speed conveying is achieved, which is suitable for high-tempo scenarios such as electronic assembly.
The double-layer multiplier chain upgrades this principle to a360° circulation system::
upper production layer: Conveys fully loaded work plates at speeds of up to 18 m/min;
lower return layer: No-load work plates return at 8 m/min energy saving;
Grabber connection: Cylinders drive the lifting mechanism to realise the upper and lower transfers, forming a closed loop.
personal viewpoint: The essence of this design is"Replacement of planar efficiency with vertical space.". In the case of an automotive factory, the deployment of a 12-metre storey plant resulted in a 2.3-fold increase in capacity per unit area - confirming the Industry 4.0 era!Vertical intensification is replacing horizontal expansion, becoming the optimal solution to high land costs.
Technical pivot point for a three-dimensional cyclic architecture
Mechanical Innovation
- Adjustable height mechanismPatented elliptical wheel lifting system (CN202222905222.0) achieves stepless adjustment of the lower level from 0.8 to 2.5 metres, compatible with different sizes of materials;
- Heavy Duty Seismic Chain: 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.
Intelligent control centre
- Synchronised anti-collision: PLC calibrates the upper and lower speed difference in real time via encoder feedback to avoid shift collisions;
- safety interlock: Automatic locking of the transfer machine when the lower level is not in position, preventing falls from height.
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 braking energy into electrical energy with a recovery rate of 23%.
The road to conquering industry scenarios
Automotive Manufacturing
- 2000kg heavy duty programme: Steel roller chain + hydraulic support platform (Patent CN219905685U) to share the 60% load;
- Synchronised Pain Cracking: 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 Guarantee: 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;
- cope with thermal expansion and contraction: Reserve 0.2mm/m expansion joint for guide rail to eliminate temperature difference 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 reduces O&M costs compared to simply upgrading materials47%.
The Triple Breakthrough of Intelligent Evolution
dynamic scheduling algorithm
- Fault Emergency Access: Lower level preset cache track, automatic diversion of workpieces in case of abnormality, and the scope of influence of failure is reduced to 30%;
- Beat Optimisation: PLC adjusts blocker timing in real time according to the workstation load, and the bottleneck 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 overhead turning sections, increase lubrication points in advance, and extend chain life by 2.8 times.
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 technology synergistic protection:
- Material Enhancement: Hardened alloy steel chain (tensile strength ≥1200MPa);
- pressure shift: Hydraulic support platform to share the 60% load (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: Economic phasing 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%.
As a double-decker speed chain carrying a car's battery pack speeds at 18m/min at a height of 15 metres, the dance of metal rollers and data algorithms is reconfiguring the dimensions of manufacturing efficiency. An automotive company's real-world testing 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 - signalling a shift in manufacturing competition from flat efficiency toData penetration wars in stereospaceIn the next ten years, the core indicator of the advanced production line will no longer be the speed of 100 metres, but the turnover precision and entropy reduction capacity of value flow per cubic metre of space. In the next ten years, the core indicator for judging the advancement of the production line will no longer be the speed of 100 metres of conveyance, but the turnover precision and entropy reduction capacity of the value flow in each cubic metre of space.
