Modular Free Flow Chain Conveyor Line

The modular free flow chain conveyor system utilizes a differential chain mechanism enabling pallets to travel at double the chain speed, ensuring efficient and flexible material handling. Featuring standardized aluminum or steel construction, variable-frequency drive systems, and configurable load capacities from 10kg to 1000kg per station, it supports diverse industrial applications including electronics assembly, automotive components, and logistics operations through customizable straight, curved, lift, and transfer modular units.

Modular Free Flow Chain Conveyor Line

Modular Free Flow Chain Conveyor System Technical Specifications

I. System Overview

The Modular Free Flow Chain Conveyor System is an automated conveying equipment designed with standardized, modular architecture. Its core feature utilizes the Free Flow Chain (Differential Chain) transmission principle, enabling the pallet carrying workpieces to travel at 2x the chain speed, achieving efficient and flexible material handling. Widely applied in automotive components, electronics, home appliances, and logistics industries for assembly production lines.

II. Free Flow Chain Specifications

ParameterSpecification/ValueRemarks
Chain ModelBS10 / BS12 / BS16 / BS20 / BS25 / BS30Number indicates pitch (mm)
Chain Pitch (P)10mm / 12.7mm / 16mm / 20mm / 25.4mm / 30mmBS25 (1-inch pitch) most common
Chain MaterialCarbon Steel (Black Oxide/Zinc/ Nickel Plated) / SS304/316Selected per environment
Roller MaterialEngineering Plastic (POM/Nylon) / Steel RollersPlastic rollers: quiet, wear-resistant
Tensile Strength8kN ~ 35kNIncreases with model size
Weight per Meter0.8kg/m ~ 3.5kg/mIncluding chain plates & attachments
Chain Speed Range3 ~ 25 m/minVariable frequency control
Pallet Speed6 ~ 50 m/min2× chain speed (free flow effect)
Operating Temperature-10℃ ~ +60℃ (Standard) / -40℃ ~ +150℃ (Special)Selected per application
LubricationPeriodic Manual / Automatic Lubrication SystemAutomatic recommended

III. Frame & Rail Specifications

ParameterSpecification/ValueRemarks
Frame MaterialAluminum Alloy (6063-T5) / Carbon Steel Square Tube / Stainless SteelAluminum: lightweight, aesthetic
Profile Size40×40 / 40×80 / 80×80 / 100×100 mmSelected per load capacity
Rail TypeSingle-Speed / Double-Speed / Triple-Speed RailDetermines speed multiplier
Rail MaterialHigh-Strength Aluminum / Steel RailHard anodized or hard chrome plated
Rail Width45mm / 60mm / 80mm / 100mm / 120mmMatched to pallet width
Standard Height700mm ~ 800mm (Adjustable ±50mm)Custom heights available
Straightness Accuracy≤0.5mm/mHigh-precision installation
Levelness Accuracy≤1mm/Full LengthEnsures smooth operation

IV. Power System Specifications

ParameterSpecification/ValueRemarks
Drive Motor TypeThree-Phase AC Motor (With Brake) / Servo Motor / Stepper MotorAC motor most economical
Motor Power0.37kW / 0.55kW / 0.75kW / 1.1kW / 1.5kW / 2.2kWSelected per length & load
Motor BrandSEW / Siemens / Delta / Mitsubishi / Quality Domestic BrandsCustomizable per request
Gearbox TypeRV Worm Gearbox / Planetary Gearbox / Helical GearboxRV gearbox: self-locking
Gear Ratio1:10 / 1:15 / 1:20 / 1:25 / 1:30 / 1:40 / 1:50Matched to speed requirements
Speed ControlVFD (Variable Frequency Drive) / Servo DriveVFD most commonly used
Transmission MethodSprocket-Chain / Timing Belt / Direct CouplingSprocket most reliable
Drive/Tail Sprocket Teeth10T / 12T / 14T / 16T / 20TT = Number of Teeth
Drive Shaft DiameterØ20mm / Ø25mm / Ø30mm / Ø35mm / Ø40mmSelected per torque
Tensioning MethodScrew Tension / Spring Tension / Pneumatic TensionScrew tension most common
Positioning Accuracy±0.5mm / ±1mm / ±3mmDepends on control method

V. Load Capacity Specifications

ParameterSpecification/ValueRemarks
Single Station Load10kg / 20kg / 50kg / 100kg / 200kg / 500kg / 1000kgPer pallet capacity
Total Line Load500kg ~ 5000kgTotal system capacity
Chain Limit LoadPer model: 500kg/m ~ 3000kg/mUniformly distributed load
Pallet Dimensions240×240 / 300×300 / 400×400 / 500×500 / 600×600 / 800×800 / 1000×1000 mm / CustomStandard or non-standard
Pallet MaterialPhenolic Resin (Bakelite) / Aluminum / Steel / Engineering PlasticBakelite most common
Pallet Thickness15mm / 18mm / 20mm / 25mm / 30mmSelected per load
Accumulation CapabilityAllows pallet stacking at drive sectionsRequires accumulation mechanism

VI. Control System Specifications

ParameterSpecification/ValueRemarks
Control MethodPLC Control / Relay Control / Industrial PCPLC most common (Siemens/Mitsubishi/Omron)
Communication ProtocolProfinet / EtherCAT / EtherNet/IP / Modbus TCP / RS485Optional
Sensor TypesPhotoelectric / Proximity / Limit Switches / EncoderFor position detection
Safety ProtectionE-Stop Buttons / Safety Light Curtains / Door Interlocks / Overload ProtectionCompliant with ISO safety standards
HMI InterfaceTouch Screen / Push Button Panel7″ / 10″ touch screens
Power SupplyThree-Phase 380V±10% / 50Hz or Single-Phase 220VConfigured per power
Protection RatingIP54 / IP65Selected per environment

VII. Modular Unit Types

Module TypeFunction DescriptionSpecification Range
Straight SectionStandard linear conveyingLength: 500mm ~ 6000mm/section
Horizontal Curve90° / 180° horizontal turnsRadius: R400 ~ R1500mm
Vertical LiftElevation between dual-level linesStroke: 500mm ~ 3000mm
Lift-Transfer UnitPallet lift & horizontal transferLift stroke: 50mm ~ 100mm
Lift-Rotate UnitPallet lift & 90°/180° rotationRotation accuracy: ±0.5mm
Stop-Positioning UnitPrecise pallet positioning stopPositioning accuracy: ±0.3mm
Flow Rack TransferDocking with gravity flow racksWidth matched
Lift-Return UnitUpper/lower level circulationCustom lift height

VIII. Application Selection Guide

ApplicationRecommended ChainMotor PowerStation LoadTypical SpeedFrame Material
Small Electronic ComponentsBS10 / BS120.37kW≤10kg5-10m/minAluminum
Phone/Computer AssemblyBS16 / BS200.55kW≤20kg8-15m/minAluminum
Home Appliance (Washer/Fridge)BS250.75kW≤100kg10-18m/minAluminum/Steel
Automotive ComponentsBS25 / BS301.1-1.5kW≤200kg12-20m/minSteel
Heavy Motor/Gearbox AssemblyBS30 / Custom2.2kW+≤1000kg5-15m/minHeavy-Duty Steel
Logistics SortingBS250.75-1.1kW≤50kg15-25m/minAluminum

IX. Installation & Maintenance Requirements

ItemRequirements
Installation EnvironmentIndoor, dry, non-corrosive, temperature -10℃~+40℃
Floor RequirementsLevel concrete floor, levelness error ≤3mm/㎡
Power RequirementsStable 3-phase 5-wire supply, voltage fluctuation ≤±10%
Daily MaintenanceChain lubrication monthly; rail cleaning weekly; motor inspection quarterly
Wear PartsFree Flow Chain (life 3-5 years), rollers, rail wear strips, drive sprockets
Spare Parts Inventory10% chain links, 5% rollers, 1 set drive components recommended

For detailed selection calculations (torque calculation, chain tension verification, motor power validation) or 3D layout recommendations for specific applications, please provide additional operational parameters.

Application Scope and Suitable Factory Types for Free Flow Chain Conveyors

I. Core Application Fields

Free flow chain conveyor systems, characterized by accumulation conveying, flexible assembly, and efficient flow, are primarily applied in the following scenarios:

II. Key Applicable Industries and Factory Types

Industry CategorySpecific Factory TypesTypical Applications
Automotive ManufacturingAuto component factories, engine assembly plants, transmission factories, automotive electronics plantsEngine assembly, transmission assembly, seat/dashboard assembly, wiring harness assembly
Electronics & AppliancesMobile phone/computer manufacturing plants, home appliance factories (air conditioner/refrigerator/washing machine), power supply/charger factoriesPCBA insertion assembly, machine assembly, aging test lines, packaging lines
New EnergyLithium battery factories, photovoltaic module plants, motor & control system factoriesBattery module assembly, Pack lines, inverter assembly, motor stator/rotor assembly
Machinery & EquipmentConstruction machinery plants, agricultural machinery plants, hydraulic component factoriesHydraulic valve assembly, gearbox assembly, small engine assembly
Medical DevicesMedical equipment manufacturing plants, diagnostic instrument factories, consumable product factoriesSyringe assembly, infusion set assembly, small medical device assembly
Food & Daily ChemicalsBeverage filling plants, cosmetic factories, cleaning product factoriesBottle filling & capping, box product assembly, end-of-line packaging
Logistics & WarehousingE-commerce logistics centers, express sorting centers, pharmaceutical distribution centersSorting conveyor lines, merging/diverging systems, AS/RS inbound/outbound
Hardware & PlasticsLock factories, sanitary hardware plants, plastic product factoriesLock cylinder assembly, faucet cartridge assembly, injection molding post-processing

III. Factory Characteristics Suitable for Adoption

✅ Recommended Conditions for Free Flow Chain Conveyors:

CharacteristicSpecific Description
Multi-station Continuous AssemblyProducts require progressive assembly through 10+ workstations
Flexible Manufacturing NeedsFrequent changeovers, variable product specifications, requiring rapid line adjustment
Takt-time ProductionStrict production takt time control, such as 60JPH (60 units per hour) in automotive industry
Accumulation Buffer RequirementsBuffering needed between stations, allowing certain stations to stop without affecting entire line
Pallet-based CarryingProducts require positioning on pallets for precision assembly or inspection
Intensive Human-machine CollaborationWorkstations primarily for manual assembly, requiring comfortable standing working height (750mm±50mm)
Light-to-heavy Mixed LoadsSingle piece weight 10kg~500kg, neither too light (belt conveyor applicable) nor too heavy (floor track line required)

❌ Unsuitable Scenarios:

ScenarioAlternative Solution
Continuous high-speed conveying (>30m/min) without accumulationBelt conveyor, roller conveyor
Heavy workpieces (>1 ton) or high-torque assemblySlat chain conveyor, floor-track robot
Dusty/humid harsh environments (mining, port)Heavy-duty apron conveyor, scraper conveyor
Simple point-to-point conveying without assembly stationsStandard belt conveyor or AGV
Extremely high cleanliness (Class 100)Cleanroom-specific FFU belt conveyor

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