The client is a large-scale carbon and graphite material manufacturing enterprise located in Inner Mongolia. The facility primarily produces carbon electrodes, graphite blocks and industrial carbon raw materials—bulky, high-specific-gravity workpieces that require stable, high-capacity vertical transportation between floor levels during production and kiln feeding processes. Consequently, the client maintains strict standards for equipment load stability, continuous operation capability and industrial dust resistance. We designed and customized a heavy-duty 5-ton dual VRC vertical lift system for this client; the project—encompassing layout optimization, structural reinforcement, electrical programming and on-site commissioning—has now been successfully completed, and the dual lifting units are fully operational in the production line.

Zorluk ve Çözüm

Müşteri Zorlukları

The carbon material production workflow in the Inner Mongolia factory faced multiple handling bottlenecks due to heavy load characteristics, large workpiece size and harsh dust-intensive environments. The multi-floor vertical transportation of carbon blocks and raw materials brought prominent operational and safety risks.

Dynamic Load and Impact Shift: Single transportation load up to 5 tons of solid carbon materials generates huge dynamic impact during vertical lifting and stopping. Traditional single VRC equipment is prone to frame vibration and platform offset, causing unstable material placement and potential safety hazards.

Structural Deflection under Long-Term Heavy Load: Long-term frequent lifting of high-density carbon workpieces leads to localized stress concentration on the lifting platform and guide rail frame. Ordinary light-duty vertical lifts easily produce structural deflection, guide rail deformation and chain jamming, affecting production continuity.

Single-Station Efficiency Bottleneck & Line Congestion: The original single-lift mode could not match the factory’s high-frequency feeding and discharging rhythm. Uninterrupted material stacking occurred at the upper and lower floor transfer points, resulting in long waiting time and restricting overall production throughput.

On-Site Layout and Space Constraints: The factory’s existing production corridor reserved limited installation space. It required dual independent lifting channels to be arranged compactly without occupying production passage, while ensuring synchronous interlocking operation of the two sets of equipment.

Harsh Dust Environment Adaptation: Carbon powder is fine, abrasive and highly permeable. Ordinary electrical components and transmission structures are easily worn and blocked, requiring high dust-proof, sealing and continuous heavy-duty operation standards for the entire equipment.

GRADIN Özel Çözüm

To solve the long-term heavy-load handling and efficiency bottlenecks of the carbon factory, our engineering team developed a customized dual-station vertical reciprocating conveyor system: VRC-5000-DUAL. This solution integrates two sets of independent heavy-duty VRC lifting frames, synchronous PLC interlocking control and dust-proof heavy-load transmission systems, realizing stable, high-efficiency and uninterrupted vertical transportation of 5-ton carbon workpieces.

1. Dual-Action Kinematic Architecture

The whole machine adopts dual independent heavy-duty vertical lifting frames, constructed from 200*200*6mm thickened square steel integral welding structure. Each single VRC unit is designed with a super rigid guide rail support structure, ensuring no structural deflection under 5-ton full-load long-term operation. The effective lifting height reaches 4200mm, adapting to the factory’s two-floor vertical transportation distance. The dual-platform staggered operation layout makes full use of the limited corridor space, realizing alternating feeding and discharging without mutual interference, and perfectly matching the on-site compact installation environment.

2. Synchronized Hydraulic and Mechanical Load Management

Each lifting unit adopts four-point synchronous chain-hydraulic hybrid lifting structure. The heavy-load hydraulic power unit provides stable lifting torque, effectively balancing the dynamic gravity shift of 5-ton carbon blocks during ascending and descending. Equipped with pressure-retaining hydraulic valves and buffer deceleration devices, the system realizes smooth start and stop, avoids inertial impact and platform shaking, and ensures zero offset and stable placement of heavy workpieces during the whole lifting stroke.

3. Dual-Station Synchronized Conveying & Docking Logic

The two sets of VRC platforms adopt 3500*2200mm oversized heavy-load bearing platforms, which can fully adapt to the placement of large carbon moulds and bulk carbon blocks. Through SIEMENS industrial PLC programming, the dual equipment realizes intelligent alternating operation: when one platform completes upper-layer discharging and returns to the lower floor, the other platform automatically starts feeding and lifting. The whole process achieves seamless docking with the factory’s upper and lower conveyor lines, eliminating manual transfer and waiting gaps.

4. Electrical and Safety Integration

The equipment is customized for China’s 380V/50Hz industrial three-phase power standard. All electrical cabinets, sensors and limit components adopt IP65 dust-proof and fully sealed design, which can effectively resist carbon powder erosion and adhesion in harsh workshop environments. The system includes:

Dual-Unit Interlock Protection: Prevent simultaneous misoperation of two sets of equipment to ensure orderly alternating operation.

Full-Stroke Anti-Fall Safety Lock: Equipped with mechanical safety anti-fall device and chain breakage protection for each lifting unit.

Multi-Point Emergency Stop System: Independent emergency stop buttons are configured on the upper floor, lower floor and equipment body to realize rapid power-off protection.

Teknik Parametreler & Destekleyici Markalar

Teknik Parametreler

Parametre	Şartname
Nominal Yük Kapasitesi	5,000 kg (5 Metric Tons) / Per Unit
Platform Boyutları	3500 mm x 2200 mm
Kaldırma Stroku (Yükseklik)	4200 mm
Working Mode	Dual-Station Alternating Synchronous Operation
Main Frame Material	2002006mm Thickened Square Steel Integral Welding
Lifting Drive Mode	Hydraulic + Four-Point Synchronous Chain Lifting
Hydraulic Power Unit	Heavy-Duty Constant-Pressure Hydraulic Station
Kontrol Sistemi	SIEMENS PLC Intelligent Interlock Control
Input Voltage	380V / 50Hz / 3-Phase (CN Standard)
Koruma Derecesi	IP65 (Dust-Proof & Sealed)
Surface Finish	Industrial Anti-Corrosion & Wear-Resistant Spray Coating
Safety Compliance	CE Certified / GB Industrial Mechanical Safety Standard

Destekleyen Markalar

Our customized VRC vertical lifting equipment adopts premium imported and domestic brand components for electric control, pneumatic, hydraulic and mechanical parts to ensure long-term stable heavy-duty operation.

1. Elektrik Kontrol Bileşenleri

Kaliteli parçalar hassas ve istikrarlı çalışma sağlar

• SIEMENS: PLC, intelligent control module, low-voltage control components

• MITSUBISHI: Auxiliary drive and signal feedback system

2. Pnömatik ve Hidrolik Bileşenler

Guarantee steady lifting and high load capacity

• SMC: Pneumatic control accessories and buffer components

• REXROTH: Hydraulic control valves, pressure stabilizing pump station

3. Mekanik Transmisyon Parçaları

Solid structure enables smooth long-term heavy-duty running

• HIWIN: Precision guide rail auxiliary positioning parts

• NSK: High-load rotating and bearing components

4. Alçak Gerilim Dağıtım Parçaları

• CHINT/DELIXI: Circuit breakers and safety switch components

• EATON: Industrial safety distribution accessories

Proje Yürütme ve Başarılar

Uygulama Detayları

Uygulama ve Başarılar

For the large-scale carbon material manufacturing factory in Inner Mongolia, we provided a customized heavy-duty 5-Ton Dual VRC vertical reciprocating conveyor system. This dual-station automated lifting solution replaces the original inefficient single-lift and manual auxiliary handling mode. It effectively solves the problems of low vertical transportation efficiency, easy equipment deformation, frequent line congestion and high potential safety hazards in carbon material production.

1. All-In-One Integrated Process Optimization

Traditional carbon production relies on single vertical lifting and manual auxiliary handling, with frequent material stacking, long cycle intervals and repeated positioning correction. This dual VRC system realizes automatic alternating lifting, stable floor docking and continuous material supply in one set of integrated equipment. It eliminates intermediate manual handling links, streamlines the multi-floor logistics process, and greatly improves the overall operational continuity of the production line.

2. Greatly Improved Production Efficiency

The original single-station lifting mode had long waiting and switching time, which seriously restricted factory daily output. The dual VRC synchronous and alternating operation mechanism realizes non-stop material feeding and discharging, forming a stable and efficient vertical logistics loop. It improves comprehensive vertical handling efficiency by over 85%, greatly shortens the material supply cycle of carbon product processing and kiln feeding, and significantly increases the factory’s daily production throughput.

3. Stable Processing Accuracy & Zero Workpiece Damage

Manual cooperation and unstable single-lift operation easily cause carbon block collision, displacement and corner damage, resulting in high product rework rate. The heavy-duty reinforced steel structure and constant-pressure hydraulic balance system of the dual VRC equipment ensure zero vibration and zero offset during full-load operation. The precise floor docking realizes stable and impact-free material transportation, achieving zero damage to carbon workpieces and effectively reducing production waste and rework costs.

4. Remarkable Labor Cost Reduction

The traditional process requires multiple workers to cooperate in material stacking, auxiliary lifting and floor docking transportation. This automated dual VRC system supports single-person unattended operation for the whole process. It greatly reduces on-site labor dependence, eliminates efficiency differences caused by manual operation, and maintains high-frequency, stable and consistent production output all day long.

5. Heavy-Duty Customization for Carbon Factory Working Conditions

Tailored for the heavy-load, high-dust and continuous intensive working environment of carbon factories, the whole machine adopts thickened fully welded steel structure and industrial dust-proof sealing design. The 5-ton super heavy-load capacity perfectly adapts to the transportation demand of large and high-density carbon workpieces. The dual-station integrated design fully meets the long-term, high-strength and uninterrupted operation requirements of Inner Mongolia carbon industrial production projects.

Genel Proje Faydaları

After equipment commissioning and formal operation, the client’s carbon material production line achieved 85%+ handling efficiency improvement, effectively reduced workpiece damage rate and on-site labor investment. The whole vertical logistics process realized integrated, automated and standardized operation, greatly optimizing the factory’s production rhythm and significantly improving overall production capacity and core market competitiveness.

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Teknik Tavsiyeye mi İhtiyacınız Var?

Karbon Fabrikası Malzeme Taşıma için Verimlilik Yükseltme | Ağır Hizmet Tipi 5 Tonluk Çift VRC Sistemi (İç Moğolistan)

Müşteriye Genel Bakış

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