Double-Plus Chain Conveyor System

1. Product Overview

A Double-Plus Chain Conveyor System (also known as a double-speed chain conveyor or free-flow conveyor) is an advanced material handling solution designed for high-efficiency assembly and production lines. Unlike conventional chain conveyors, this system uses a unique roller-chain structure to achieve 2–3× higher pallet speed than the chain itself, significantly improving throughput without increasing motor power.

This system is widely used in automated manufacturing environments, where products need to be transported, positioned, accumulated, and processed at multiple workstations.

Key Features:

• Speed multiplication (up to 2.5×)
• Pallet-based conveying (flexible carriers)
• Accumulation and buffering capability
• Modular and customizable structure
• High load capacity with stable operation

2. Working Principle

The core innovation of a Double-Plus Chain Conveyor lies in its differential speed mechanism.

How It Works:

1. Dual Roller Structure
   • Each chain link includes two rollers (large and small diameter).
   • The outer roller runs on the guide rail; the inner roller supports the pallet.
2. Speed Amplification Effect
   • Due to the diameter difference, pallets move 2–3 times faster than the chain speed.
3. Friction-Driven Motion
   • The interaction between rollers and rails creates accelerated pallet movement without increasing motor speed.
4. Independent Pallet Control
   With stoppers and sensors, pallets can:
   • Stop
   • Accumulate
   • Index precisely
   • Resume movement independently
5. Closed-Loop System
   • Empty pallets return via lifts or transfer units, forming a continuous production loop.

👉 Result:
High-speed conveying + precise workstation control + flexible production flow

Therefore, speed-plus chains are different from traditional chains. If you would like to see more comparisons between the two, please read this article:Traditional Chain Conveyor VS Double Plus Chain Conveyor

3. System Components

A typical Double-Plus Chain Conveyor System consists of:

Mechanical Components

• Double-plus conveyor chains
• Aluminum or steel frame structure
• Guide rails
• Pallets / tooling plates
• Drive motor and gearbox
• Sprockets and shafts

Control & Automation Components

• PLC control system
• Sensors (position, presence)
• Stoppers (pneumatic/electric)
• Lift & transfer units (LTU)
• HMI interface (optional)

Optional Modules

• Cross transfer systems
• Vertical lifters
• Turntables
• Buffer zones

These are chains of this conveyor system.They come in both metallic and non-metallic versions, allowing users to choose the appropriate material based on their specific needs.

4. Main Applications

Double-Plus Chain Conveyor Systems are ideal for discrete manufacturing and assembly processes requiring controlled flow.

Key Industries:

1. Electronics Manufacturing

• PCB assembly lines
• Consumer electronics production

2. Automotive Industry

• Component assembly (engines, gearboxes)
• Sub-assembly lines

3. Home Appliance Manufacturing

• Washing machines, refrigerators, air conditioners

4. Industrial Equipment

• Mechanical assemblies
• Modular product lines

5. Smart Logistics & Warehousing

• Pallet circulation systems
• Automated transfer lines

The image above shows an automated double-plus chain conveyor system used to transport electrical components.Undoubtedly, the double-plus chain conveyor has become one of the most important assembly lines due to its flexibility and versatility.

5. Problems Solved (Customer Pain Points)

1. Low Production Efficiency

Traditional conveyors move at fixed speeds.
✔ Double-plus systems increase throughput without increasing energy consumption.

2. Lack of Process Flexibility

Conventional systems cannot handle multi-station timing differences.
✔ Enables independent workstation control and buffering.

3. Manual Handling & Labor Cost

Manual pallet movement reduces efficiency and increases errors.
✔ Fully automated pallet circulation eliminates manual intervention.

4. Space Constraints

Linear conveyors require large footprints.
✔ Compact layout with loop systems, vertical lifts, and transfers.

5. Product Damage & Instability

Unstable transport affects product quality.
✔ Smooth, controlled movement reduces vibration and improves consistency.

6. Advantages of Double-Plus Chain Conveyor

7. Competitive Analysis

Double-Plus Chain vs Other Conveyor Types

If you want to know which conveyor is right for you,pls view this article :What Kind of Conveyor System Is Suitable for You?

Why Choose Double-Plus Chain?

Compared to traditional conveyors:

• 2–3× faster pallet movement
• Better synchronization with automation systems
• Supports mixed-model production

👉 It is the best balance between speed, flexibility, and control in modern assembly lines.

8. Customization Options

We provide fully customized solutions based on your production requirements:

• Conveyor length, width, and height
• Load capacity (light to heavy-duty)
• Pallet size and material
• Speed and control logic
• Integration with robots or inspection systems
• Layout design (loop, straight, multi-line)

9. Why Choose Our Double-Plus Chain Conveyor System

• In-house mechanical + electrical + software engineering
• Strong experience in non-standard automation systems
• High-quality components for long service life
• Full support from design → manufacturing → installation → after-sales
• Flexible solutions for small factories to large-scale production lines

If you need a conveyor but dont know how to choose it,pls contact us.We are a powerful conveyor factory with customization capabilities.We will give you professional advice to help you choose the right product more quickly and accurately.Or add our sales manager to get a quick response(What’s App +8615562680658 Sophia)

10. Conclusion

The Double-Plus Chain Conveyor System is a high-performance, flexible, and intelligent solution for modern manufacturing.

By combining speed amplification, precise control, and modular design, it solves critical production challenges such as:

• Low efficiency
• Poor workflow coordination
• High labor costs
• Limited scalability

If your goal is to build a smart, automated, and scalable production line, this system is one of the most reliable and future-proof choices available.