The client is a large-scale industrial finished goods warehouse located in Jiangsu, China. The facility primarily stores palletized industrial products and undertakes frequent inter-floor material turnover between the ground floor and mezzanine storage area—workflows that require high stability, precise docking and continuous handling capacity during repetitive vertical transportation. Consequently, the client maintains rigorous standards regarding equipment running stability, safety performance and long-duration operational reliability. We designed and customized a 2-ton heavy-duty vertical reciprocating conveyor workstation for this client; the project—encompassing structural customization, hydraulic optimization, electrical programming and on-site commissioning—has now been successfully completed, and the unit is fully operational.

Défi et solution

Défis pour les clients

The multi-layer warehouse logistics workflow faced several engineering bottlenecks associated with frequent pallet circulation, limited aisle space and humid indoor working conditions. The traditional forklift and manual auxiliary handling mode posed significant operational risks and efficiency losses.

Dynamic Offset and Eccentric Load Risk: Irregular stacked pallets cause constant eccentric load during vertical transportation. Ordinary lifting structures produce lateral offset and platform shaking, bringing hidden dangers of pallet sliding and cargo falling during lifting.

Structural Deflection under Repetitive Load: Long-term high-frequency 2-ton load circulation leads to fatigue pressure on conventional lifting frames. Standard single-column lift equipment easily suffers guide rail deviation and structural deformation, resulting in unstable docking and frequent equipment failure.

Interface Synchronization and Docking Accuracy: The warehouse requires precise millimeter-level height matching between ground floor and 3.6m mezzanine. Inaccurate platform positioning causes pallet jamming, unsmooth transfer and secondary cargo collision during loading and unloading.

Spatial and Layout Constraints: Traditional forklift ramps occupy a large aisle area, resulting in cramped warehouse passages, serious peak-time congestion and wasted storage space. The client required a compact vertical lifting solution without occupying logistics passages.

Humid Environment Electrical Adaptability: The indoor warehouse maintains long-term humid air, which easily causes damp short circuit, dust accumulation and aging of ordinary electrical components, requiring high-level sealed and moisture-proof electrical configuration.

Solution personnalisée GRADIN

To address the technical requirements of the Jiangsu warehouse logistics upgrade, our engineering team developed a specialized vertical lifting unit: VRC-2000-IND. This machine integrates a heavy-duty four-post rigid frame, dual synchronous hydraulic lifting system and PLC automatic roller docking system, realizing stable, safe and unmanned vertical pallet transportation.

1. Architecture cinématique à double action

The structural foundation utilizes a custom four-post vertical frame constructed from 160x160x5mm thickened rectangular tubing with full integral welding. This rigid frame structure provides a 3600mm vertical stroke, perfectly matching the warehouse mezzanine height and realizing accurate floor-to-floor vertical transportation. The four-sided guide rail limiting design effectively resists eccentric load pressure, keeping the platform horizontal all the time. The compact frame layout saves traditional forklift ramp space, maximizing the client’s internal warehouse storage area.

2. Synchronized Hydraulic and Torque Management

Managing dynamic eccentric load and platform stability during high-frequency lifting is achieved through a dual-cylinder synchronous actuation system. The vertical lift phase utilizes dual Φ70-55mm hydraulic cylinders with balanced pressure output. To prevent platform shaking and cargo displacement under uneven pallet load, the hydraulic circuit is equipped with pressure-compensated flow control valves and hydraulic self-locking devices. These valves ensure stable start, uniform lifting speed and buffer deceleration stop, protecting both the mechanical frame structure and palletized finished goods.

3. Integrated Powered Roller Conveyor

The platform surface (2800 x 1500 mm) is fitted with heavy-duty motor-driven roller conveyor. Once the platform reaches the precise horizontal docking height of the target floor and completes mechanical locking, the 2.2kW high-torque motor activates automatically. The rollers are precision-aligned on the integral steel frame to ensure zero-deflection and smooth pallet transfer. This automated handover eliminates manual auxiliary handling and ensures consistent and continuous material feeding, synchronized via Siemens industrial PLC automation logic.

4. Intégration de l'électricité et de la sécurité

The power unit was specifically built for the Chinese 380V/50Hz 3-phase grid. All electrical terminations and sensor components adopt IP65 fully sealed protection to resist indoor humidity and dust erosion in warehouse environments. The system includes:

Electronic Limit Switches: To ensure precise height positioning and strict interlocked sequence of lifting and stopping.

Mechanical Safety Anti-Fall Locks: Full-stroke locking protection to prevent platform falling under unexpected chain or oil circuit failure.

Emergency Stop Redundancy: Accessible at both ground operation panel and mezzanine control point for dual safety protection.

Paramètres techniques et marques de soutien

Paramètres techniques

Paramètres	Spécifications
Capacité de charge nominale	2,000 kg (2 Metric Tons)
Dimensions de la plate-forme	2,000 mm (W) x 2,000 mm (D)
Cabin Inner Dimensions	W1,800 mm x L1,800 mm x H2,500 mm
Max Cargo Dimensions	1,700 mm (W) x 1,700 mm (D) x 2,400 mm (H)
Structural Frame Material	120×80×4mm Square Tube + 4mm Flat Steel Plate (Laiwu Steel)
Main Column Material	150×4mm Square Carbon Steel Tubing (Laiwu Steel)
Lift Cabin Fabrication	TISCO 304 Stainless Steel Construction
Lifting Guide Rails	Elevator-Grade Special T-Type Guide Rails (T90)
Lifting Transmission System	Hangzhou Donghua 20B-1 Driving Chain & 20B Sprockets
Control & Drive System	Siemens SIMATIC PLC + Siemens VFD Variable Frequency Drive
Human Machine Interface	Kinco HMI Touchscreen
Safety Induction System	Epsi Light Curtains + Omron/SICK Photoelectric Sensors
Low-Voltage Electrical Components	Schneider Electric Contactors & Control Buttons
Fire Protection Configuration	Inorganic Fabric Fireproof Rapid-Roll Doors
Lifting Positioning Accuracy	± 5 mm (Closed-loop positional alignment)
Safety Protection Configuration	Overspeed Governor + Safety Gear Linkage + Rubber Buffers
Shaft Enclosure Structure	Rectangular Tube Skeleton + Steel Wire-Mesh Cladding
Designed System Lifespan	15 Years
Tension d'entrée	380V / 50Hz / triphasé (norme CN)
Indice de protection	IP65 (Moisture & Dust Proof)
Finition de la surface	Industrial Grade Anti-Corrosive & Moisture-Proof Coating
Conformité en matière de sécurité	CE Certified / GB Industrial Lifting Standard

Soutien aux marques

Our vertical conveyor machines adopt premium imported and domestic brand components for electric control, safety induction, mechanical transmission and low-voltage distribution parts, ensuring high-precision, durable and stable long-term operation of warehouse lifting equipment.

1. Composants de commande électrique

High-end industrial control parts ensure precise frequency conversion regulation and stable program operation

•SIEMENS: SIMATIC PLC core controller, VFD variable frequency drive system

•Kinco: Industrial HMI touchscreen human-machine interaction terminal

2. Safety & Induction Components

High-sensitivity induction parts guarantee zero-misjudgment safety protection and anti-collision performance

•Epsi: High-precision safety light curtain protection system

•Omron / SICK: Industrial photoelectric sensing and detection components

3. Pièces de transmission mécanique

High-strength transmission accessories support long-term high-frequency heavy-duty operation

•Hangzhou Donghua: 20B-1 driving chains and 20B professional sprockets

•Elevator-Grade T90: Special T-type guide rails for stable vertical lifting

4. Low Voltage Distribution & Fireproof Parts

•Schneider Electric: Low-voltage contactors, relays and control buttons

•Fireproof Accessories: Inorganic fabric fireproof rapid-roll isolation doors

Exécution du projet et réalisations

Détails de la mise en œuvre

Exécution et réalisations

For an industrial warehouse in Jiangsu, China, we provided a customized 2-Ton Heavy-Duty Vertical Reciprocating Conveyor System. This all-in-one handling solution integrates vertical lifting and automatic roller conveying functions in one unit, replacing disjointed forklift and manual semi-automatic handling processes. It effectively solves the problems of fragmented workflow, channel congestion, low throughput and high cargo damage rate in warehouse multi-floor logistics.

1. Optimisation des processus intégrés tout-en-un

Traditional warehouse logistics requires forklift climbing and manual pallet transfer for inter-floor transportation, resulting in frequent workpiece transfer, long cycle time and repeated positioning correction. This integrated VRC system realizes automatic height adjustment, precise floor docking and continuous roller feeding in one station. It eliminates intermediate handling links, streamlines the production process and greatly improves operational continuity.

2. Une efficacité de production nettement améliorée

The original segmented operation mode leads to long waiting and switching time, restricting overall warehouse throughput. The synchronized hydraulic lifting and powered roller conveying work coordinately to achieve one-stop pallet transportation. It improves comprehensive logistics efficiency by over 78%, shortens the material turnover cycle, and significantly increases daily inbound and outbound volume.

3. Précision de traitement stable et absence de dommages aux pièces à usiner

Manual forklift transfer and repeated docking easily cause pallet displacement, surface abrasion and corner damage, leading to high rework rates. The heavy-duty integrated structure features stable load-bearing and balanced hydraulic lifting. The powered roller conveyor ensures smooth material feeding without impact, realizing precise positioning and zero damage to warehouse goods, effectively reducing waste and rework costs.

4. Réduction remarquable des coûts de main-d'œuvre

The traditional process requires multiple workers to cooperate in forklift driving, pallet aligning and inter-floor transporting. This automated integrated equipment supports single-person operation for the whole process. It reduces labor dependence, avoids efficiency differences caused by manual operation, and maintains stable and high-frequency logistics output.

5. Space-Saving Customization for Warehouse Working Conditions

Tailored for compact, humid and high-frequency operation warehouse environments, the whole machine adopts thickened steel structure and moisture-proof & dust-proof treatment. The 2-ton rated load perfectly adapts to conventional industrial pallet transportation demands. The compact vertical design saves valuable aisle space and increases effective storage area, fully meeting the long-term stable operation requirements of modern warehouse logistics projects.

Avantages globaux du projet

After equipment commissioning and operation, the client’s warehouse logistics system achieved 78%+ efficiency improvement, fewer defective goods and reduced labor investment. The whole production process realized integrated, automated and standardized handling, greatly improving warehouse space utilization, daily throughput and core operational competitiveness.

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Présentation du client

Profil du client