9.18.2025 / 5-minute read

5-Ton Parallel Reciprocating Lifts in Inner Mongolia Carbon Lights-Out Factory

Overview

This case analysis details the material handling solution for a “lights-out factory” in Inner Mongolia Autonomous Region.

To efficiently transport finished carbon blocks between two workshops with significant level differences at a fast production pace, two parallel reciprocating lifts were deployed.

Since commissioning on August 15, 2025, the system has operated reliably under high-frequency, heavy-duty conditions with zero production-impacting issues.

Basic Parameters

Parameter	Value
Model	SJLT5.0-5.0
Rated Load	5000 kg
Car Size	2200×2200×1200 mm
Platform Size	2200×2200 mm
Required Space	3200×2600 mm
Travel Height	5000 mm
Lifting Speed	0-30 m/min (Avg. ~20 m/min over 5m due to acceleration)
Stations	2 stops, 2 stations
Positioning Accuracy	±15 mm
Drive Unit	22KW/380V SEW Motor (K107DRN180L4/BE30/V-22KW)
Control System	PLC (Communication interfaces)
Pit Requirement	Pit-free installation

How It Works

The system employs two parallel 5-ton capacity reciprocating lifts.

Finished carbon blocks are conveyed onto the lift car (2200x2200mm) via customer-supplied roller lines.

Photoelectric sensors detect the load, triggering a 22KW SEW gearmotor to lift the cargo vertically 5 meters at speeds up to 20 m/min.

After precise positioning, the blocks are discharged into the adjacent workshop, enabling fully automated, rapid inter-floor transportation.

The Challenges

Lights-Out Operation: Demanded extreme reliability and stability for fully automated operation with zero tolerance for downtime.
Fast Production Pace: Required high efficiency and rapid response for very high daily cycles.
Heavy-Duty Operation: 5-ton loads per cycle presented a significant challenge to structural integrity and the drive system.
Space Constraints: Limited installation area (3380x2900mm) required precise layout, with a fit gap in the car depth direction.
Integration Needs: Required seamless communication and control integration with customer’s roller conveyors for a fully automated line.

Solutions

Parallel Operation for Efficiency & Redundancy: Two lifts installed side-by-side meet the fast pace and provide backup during maintenance, ensuring continuous lights-out operation.
Heavy-Duty Design: Utilized national standard steel components and an integrated car-lifting structure to ensure strength and long-term durability under 5000kg loads.
Premium Core Components: A high-power 22KW SEW gearmotor provides robust and reliable power for high-frequency start-stop cycles.
Multi-Layer Safety Protection:
Fall Prevention: Mechanical safety gear to fundamentally prevent car falling.
Overload Protection: Integrated sensor locks the system if overloaded.
Cargo Detection: Photoelectric sensors prevent oversized goods from causing jams.
Electrical Protection: Control system includes emergency stop, phase-loss protection, etc.
Flexible Integration: The PLC control system provides comprehensive communication interfaces and logic for easy integration with the customer’s conveyor system, enabling intelligent coordination.