5-Ton Double VRC System for Inner Mongolia Carbon Plant

The client for this project is an industry-leading advanced carbon material manufacturer located in Tongliao, Inner Mongolia, China. This facility is a provincial-level key demonstration project operating as a fully automated, unmanned “black-light” (dark) factory . The primary logistics bottleneck involved a 5.0-meter horizontal elevation difference between two adjacent production workshops, requiring high-frequency, heavy-duty vertical transport of finished carbon blocks (weighing up to 5,000 kg per pallet) to the buffer storage area .

To support the continuous, unmanned operations of this factory, we customized and deployed a double-VRC side-by-side vertical hoist network (Model SJL15.0-5.0), which was fully commissioned on August 15, 2025 . The core project highlights include:

5-Ton High-Inertia VFD Lifting: A rated load capacity of 5,000 kg , driven by a high-torque 22 kW SEW geared motor (Model: K107DRN180L4/BE30/V-22kW) with VFD speed control ranging from 0 to 20 m/min.
Side-by-Side Redundant Layout: Designed as a side-by-side double VRC array . This dual-line setup not only doubles inter-workshop throughput but also allows continuous logistics sorting if one unit undergoes routine maintenance.
Quadruple Double-Strand Roller Chains: Driven by 4 sets of 20A-2 high-strength, double-strand alloy steel roller chains to guarantee extreme tensile fatigue resistance under 5-ton vertical loads.
Dark-Factory Automation Integration: The VRC systems feature standard factory communication interfaces . Governed by a Siemens S7-1200 PLC , they execute fully automated signal handshakes with the plant’s AGV fleets and conveyor systems without human intervention.

Challenge & Solution

Challenge

Before deploying our heavy-duty double VRC system, the factory’s inter-workshop material transport lines suffered from severe quality, safety, and efficiency bottlenecks:
1. Catastrophic Fall Hazards of a 5-Ton Load: Shuttling a 5-ton payload vertically introduces extreme safety liabilities. Any tensile chain deformation, break, or brake slip would cause the multi-ton cabin to free-fall, risking severe factory floor damage and complete line shutdown. Standard freight elevators lacked the necessary fail-safe safety factors.
2. Automation Bottlenecks in Unmanned Operations: The plant runs 24/7. Previously, relying on heavy-duty diesel forklifts and manual shuttling resulted in frequent operator errors. A single forklift breakdown or shift change immediately starved the downstream formulation line, costing thousands of dollars in hourly idle losses.
3. Leveling Drift Under Heavy Acceleration Inertia: Decelerating a 5,000 kg load generates massive dynamic forces. These dynamic shocks caused standard frames to deflect, warping the guide rails and causing leveling drift beyond the strict ±15mm tolerance , which triggered pallet jamming at the roller conveyor interfaces .
4. Conductive Carbon Dust Triggering Sensor Faults: The carbon material processing environment is highly abrasive and filled with electrically conductive carbon dust. Standard photoelectric or limit sensors quickly accumulated dust, triggering false alarms, automatic shutdowns, and short circuits inside electrical enclosures.
5. Pit Condensation and Mechanical Deterioration: Installing the VRC required a 500mm foundation pit to house buffers and structural bases . Due to the harsh winter temperature fluctuations in Inner Mongolia, condensation and moisture collected in the pit, causing structural oxidation and accelerating seal aging.

Solution

To ensure the continuous, 24/7 vertical material handling of the “black-light” factory, we customized and deployed a heavy-duty double VRC system:
1. Heavy-Duty SEW Geared Powertrain & Quadruple 20A-2 Chains:
  - High-Torque SEW Motor: Powered by a 22 kW SEW geared brake motor (Model: K107DRN180L4/BE30/V-22kW) to deliver high vertical lifting torque .
  - Quadruple Double-Strand Chains: Hoisting is driven by 4 sets of 20A-2 high-strength double-strand roller chains (Donghua) [70]. This raises the mechanical safety factor to over 8:1, preventing chain fatigue and elongation during high-frequency travel.
2. Side-by-Side Double-VRC Redundant Layout for Zero Downtime:
  - We installed two identical, independently controlled 5-ton VRC lifts side-by-side . The two Siemens PLCs coordinate with the factory’s central SCADA system . If VRC A enters a routine inspection or maintenance cycle, the material sorting line automatically redirects the active carbon block pallets to VRC B, securing “zero downtime” inter-workshop material flow.
3. High-Rigidity Steel Frame Mast & Heavy-Duty Safety Gears:
  - The structural columns utilize heavy-duty 200mm thick-wall square tubing (sourced from Laiwu Steel) and a 200x100x6mm top frame, securing extreme torsional stiffness under full load dynamics . For mechanical fall-prevention, the cabin features a Tongli SAS20 speed-limiting safety gear, a PHF gearless fall arrestor, and an XJ33/XJ34 overspeed governor linkage . In case of descending overspeed, the system mechanically clamps both the 3-ton counterweights and the 5-ton cabin onto the T90 guide rails , with polyurethane buffers absorbing residual kinetic energy .
4. Siemens S7-1200 Automation & Pitless/Pit-Recessed Integration:
  - Managed by a Siemens SIMATIC S7-1200 PLC and precise photoelectric distance measuring sensors , the platform consistently achieves a leveling accuracy of within $\pm 15$ mm , which is optimal for heavy pallet rollers. The industrial electrical panel integrates phase-loss and phase-imbalance protection relays , while supporting Modbus/TCP communication to report real-time cabin elevation, Keli load-cell weight feedback, and system status logs to the main control room .
5. SICK Dustproof Sensors and Automated PVC Rapid Doors:
  - We deployed SICK D4V107 series photoelectric switches for pallet tracking and position limits . These sensors feature advanced dust-mitigation casings that prevent conductive carbon dust from interrupting the infrared light beams. Both entrance portals are isolated by automated yellow PVC rapid doors (1.2m height) , which remain closed during travel to prevent carbon dust migration .

Technical Specifications

Parameter	Specification / Engineering Detail
Model Designation	SJL15.0-5.0 Heavy-Duty Double VRC System
Quantity Deployed	2 Sets (Side-by-side redundant layout)
Rated Load Capacity	5,000 kg (5.0 Metric Tons)
Lifting Stroke Height	5,000 mm (5.0 Meters)
Lifting Speed	0 – 20 m/min (VFD Variable Speed Control)
Lifting Geared Motor	22 kW / AC 380V / 50Hz (SEW: K107DRN180L4/BE30/V-22kW)
Platform Dimensions	2,200 mm (W) x 2,200 mm (D)
Required Shaft Space	3,380 mm (Width) x 2,900 mm (Depth)
Cabin Inner Dimensions	2,200 mm (W) x 2,200 mm (D) x 1,200 mm (H)
Max Applicable Pallet	2,000 mm x 2,000 mm
Stops & Stations	2 Stops, 2 Stations
Leveling Positioning Accuracy	$\pm 15$ mm
Main Mast Columns	200 mm Square Tubing (Laiwu Steel; Q235B)
Top Frame Material	$200 \times 100 \times 6 mm$ Rectangular Tubing (Q235B)
Lifting Guide Rails	Elevator-Grade Special T-Type Guide Rails (T90)
Driving Chain Specification	20A-2 High-Strength Double-Strand Roller Chains (Hangzhou Donghua)
Lifting Counterweight	3,000 kg (Q235 Steel, Zhongding)
Counterweight Guide Rails	Professional TK5A Elevator Guide Rails
Landing Doors	Yellow PVC Rapid-Roll Doors (W1,500 x H1,200 mm; interlocked)
Automation PLC Controller	Siemens SIMATIC S7-1200 PLC
VFD System	Mitsubishi Heavy-Duty VFD
Weighing Sensors	Keli Load Cell Assemblies
Safety Sensor Barriers	SICK D4V107 Photoelectric Safety Switches
Buzzer & Stack Light	Schneider L600b Three-Color Alarm Light & Running Buzzer
Solenoid Valves	SMC Solenoid Valves
Safety Gear Protection	SAS20 Speed-Limiting Safety Gear + PHF Gearless Fall Arrestor
Operator Interface	Pedestal IP66防水防尘 Console + Kunlun Tongtai 12″ HMI
Required Foundation	500 mm Foundation Pit depth
Designed System Lifespan	$\geq 15$ Years

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5-Ton Double VRC System for Inner Mongolia Carbon Plant

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