Non-Standard Double-Plus Chain Conveyor

What Is a Non-Standard Double-Plus Chain Conveyor?

A non-standard double-plus chain conveyor is a customized conveyor system designed for factories that require flexible, high-load, and precise material transportation solutions beyond the capabilities of standard conveyor equipment.

Unlike traditional chain conveyors, a double-plus chain conveyor uses a special roller chain structure where the conveying rollers rotate faster than the chain speed. This design reduces friction between products and the conveyor surface, allowing workpieces to accumulate, stop, buffer, and move smoothly without damaging the product surface.

The term “non-standard” means the conveyor is not built according to a fixed model. Instead, the structure, length, width, load capacity, speed, control system, and tooling are customized according to the customer’s production requirements.

It is widely used in automated production lines where products require:

• Precise positioning
• Low-friction transportation
• Temporary storage and buffering
• Multi-station assembly operations
• Integration with robots and inspection equipment

Compared with standard conveyors, non-standard double-plus chain conveyors provide higher flexibility for complex manufacturing environments.

How Is a Non-Standard Double-Plus Chain Conveyor Manufactured?

The manufacturing process usually includes engineering design, component machining, assembly, testing, and system integration.

1. Production Requirement Analysis

Before manufacturing, engineers analyze:

• Product size and weight
• Conveyor layout
• Production speed
• Working environment
• Loading requirements
• Automation level
• Connection with other machines

For example, an automotive assembly line may require a heavy-duty conveyor that carries engine parts, while an electronics factory may need a precision conveyor for small components.

2. Custom Engineering Design

Based on production requirements, engineers create:

• 3D mechanical models
• Conveyor frame designs
• Chain selection
• Motor power calculations
• Roller arrangement
• Control system design

The conveyor dimensions are customized, including:

• Length
• Width
• Height
• Conveying direction
• Number of working stations
• Product positioning methods

3. Component Manufacturing

The main structural parts are processed through:

• CNC machining
• Laser cutting
• Welding
• Surface treatment
• Precision assembly

Common materials include:

• Carbon steel for heavy-duty applications
• Stainless steel for clean environments
• Aluminum profiles for lightweight structures

4. Assembly and Testing

After manufacturing, the system is assembled and tested for:

• Running stability
• Load capacity
• Noise level
• Speed accuracy
• Positioning precision
• Safety performance

The conveyor is adjusted before delivery to ensure smooth operation on the customer’s production line.

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Main Components of a Non-Standard Double-Plus Chain Conveyor

A customized double-plus chain conveyor consists of several key components.

1. Double-Plus Chain

The double-plus chain is the core component.

It includes:

• Chain plates
• Rollers
• Bushings
• Pins

Its unique structure allows the rollers to rotate faster than the chain movement, reducing sliding friction between products and conveyor surface.

Benefits:

• Smooth transportation
• Less product damage
• Lower energy consumption
• Longer service life

2. Conveyor Frame

The frame provides structural support.

Common materials:

• Aluminum alloy profiles
• Carbon steel
• Stainless steel

The frame design depends on:

• Product weight
• Conveyor length
• Working environment

Heavy-duty industries usually require reinforced steel frames.

3. Drive System

The drive system provides the power needed for chain movement.

Main components include:

• Motor
• Gear reducer
• Drive sprocket
• Transmission shaft

Servo motors may be added when precise positioning is required.

4. Supporting Rails and Wear Strips

These components guide and support the chain.

Functions:

• Reduce friction
• Maintain chain alignment
• Improve conveyor durability

High-performance engineering plastics such as UHMW-PE are commonly used because of their wear resistance.

5. Product Pallets or Fixtures

For automated assembly lines, products are often placed on pallets.

Customized fixtures provide:

• Accurate positioning
• Stable transportation
• Easy robotic handling

6. Control System

The control system manages conveyor operation.

It may include:

• PLC controller
• Sensors
• Touch screen interface
• Frequency converter
• Safety switches

Advanced systems can communicate with factory automation networks.

Working Principle of a Double-Plus Chain Conveyor

The working principle is based on the speed difference between the chain and rollers.Check here to see how it works:Double Speed Chain Conveyor Line

Step 1: Chain Movement

The motor drives the sprocket, causing the double-plus chain to move continuously.

Step 2: Roller Rotation

Because the chain rollers contact the conveyor guide rail, they rotate faster than the chain speed.

Step 3: Product Transportation

Products placed on the rollers move forward with minimal friction.

Step 4: Accumulation Function

When products reach a blocked area or stop station:

• The chain continues moving
• Rollers rotate underneath the products
• Products remain stationary

This prevents:

• Product collision
• Surface scratches
• Motor overload

Step 5: Automated Positioning

Sensors and control systems coordinate stopping, inspection, assembly, and robotic operations.

Main Applications of Non-Standard Double-Plus Chain Conveyors

1. Automotive Manufacturing

Used for:

• Engine assembly
• Transmission assembly
• Battery module production
• Component transportation

Advantages:

• High load capacity
• Reliable operation
• Easy integration with robots

2. Electronics Manufacturing

Used for:

• PCB assembly
• Semiconductor equipment
• Precision component handling

Advantages:

• Low vibration
• Accurate positioning
• Clean operation

3. New Energy Battery Industry

Used in:

• Battery pack assembly lines
• Cell transportation
• Module testing stations

Requirements:

• Stable movement
• Precise stopping
• Safety integration

4. Home Appliance Production

Applications include:

• Washing machine assembly
• Refrigerator production
• Small appliance manufacturing

Benefits:

• Flexible layout
• Continuous production
• Reduced manual handling

5. Mechanical Equipment Assembly

Used for:

• Industrial equipment assembly
• Machine component transportation
• Multi-station production systems

What Problems Does It Solve for Factories?

1. Reduces Product Damage

Traditional conveyors create sliding friction, which can scratch or damage products.

Double-plus chain conveyors use rolling contact, reducing surface damage.

2. Improves Production Efficiency

Manual transportation causes:

• Slow movement
• High labor cost
• Production delays

Automation improves:

• Production speed
• Line balance
• Worker efficiency

3. Solves Buffering Problems

In automated factories, different stations often operate at different speeds.

The accumulation function allows products to wait temporarily without stopping the entire production line.

4. Supports Customized Production Lines

Standard conveyors cannot always match unique factory layouts.

Non-standard designs solve problems such as:

• Limited factory space
• Irregular production processes
• Special product sizes
• Complex automation requirements

5. Improves Workplace Safety

Automation reduces:

• Manual lifting
• Heavy material handling
• Operator injury risks

Non-Standard Double-Plus Chain Conveyor vs Traditional Conveyors

Double-plus chain conveyors are more suitable for automated assembly lines requiring precision and buffering.

Learn more about the difference between traditional conveyor and double-plus chain conveyor.

Competitor Analysis

1. Traditional Chain Conveyors

Advantages:

• Simple structure
• Low initial cost
• Suitable for heavy materials

Disadvantages:

• Higher friction
• Limited accumulation capability
• May damage sensitive products

Double-plus chain conveyors provide better protection and flexibility.

2. Belt Conveyors

Advantages:

• Low cost
• Quiet operation
• Suitable for lightweight products

Disadvantages:

• Limited positioning accuracy
• Belt wear issues
• Difficult maintenance for long systems

For precision manufacturing, double-plus chain conveyors offer better performance.

3. Roller Conveyors

Advantages:

• Simple design
• Good for cartons and pallets

Disadvantages:

• Poor control of product movement
• Limited automation capability

Double-plus chain conveyors provide better control for intelligent production lines.

Why Choose a Non-Standard Double-Plus Chain Conveyor?

A non-standard double-plus chain conveyor is not just a transportation device. It is a customized automation solution designed around the factory’s production process.

Key advantages include:

• Customized structure and dimensions
• High load capacity
• Smooth and low-friction operation
• Strong accumulation capability
• Precise product positioning
• Easy integration with robots and inspection systems
• Long service life

For manufacturers upgrading toward smart factories and automated production, a customized double-plus chain conveyor provides a reliable foundation for efficient, flexible, and stable material handling.