RESOURCE CENTER > CASE STUDIES

Dual Rail Freight Lift for Japanese Electrical Equipment Plant

Q: Why adapt to 200V/60Hz? Can‘t we just use 220V/380V?

Japan‘s industrial power standard is 3-phase 200V/60Hz – completely different from China‘s 380V/50Hz. Using standard Chinese equipment would require additional transformers and frequency converters on arrival – increasing cost and consuming valuable shaft space. We customise all motors, pumps, and electrical components to 200V/60Hz at the factory. The client can connect directly to factory power upon arrival – no conversion equipment needed.

Q: The lift shares a 20GP container with another unit – how do you prevent damage?

Sharing a 20GP container requires optimised loading and secure lashing . The guide rails are shipped in two sections (3.8m each), the lifting frame is welded to the platform to minimise loose parts – all with bare packing, rust protection, and fixed lashing. Cross-loaded with the other unit to maximise container space. All securing points are calculated to prevent shifting or collision during sea freight.

POSTED: 21/7/2026

Overview

Project Type: Guide rail hydraulic lift (single-cylinder dual-rail)
Client: KOBAYASHI DENSO CO., LTD. (Japan)
Installation Location: Fukuyama City, Hiroshima Prefecture, Japan
Industry: Industrial manufacturing / warehousing logistics
Core Function: Vertical goods conveying inside a shaft (2 stops / 2 levels)

Industry Context

KOBAYASHI DENSO CO., LTD. is located in Fukuyama City, Hiroshima Prefecture, Japan. Japanese manufacturing is known for its lean, high-standard operations, with strict requirements for safety, reliability, and space utilisation in material handling equipment.

This lift is installed inside a shaft at the client‘s factory (shaft dimensions: 1940×1760×7800mm) for vertical goods conveying between two floors. Japanese factories typically face space constraints, placing high demands on the footprint and shaft adaptability of any installed equipment.

Core requirements:

Install a 1-ton capacity freight lift within a limited shaft space
4.6m travel with 2 stops / 2 levels
Equipment must adapt to Japanese power supply standards (3-phase 200V/60Hz)
Compact packaging for shared 20GP container shipping

Basic Parameters

Parameter	Value
Rated load	1000 kg
Travel height	4.6 m (2 stops / 2 levels)
Platform size (W×D)	1800×1400 mm
Shaft size (W×D×H)	1940×1760×7800 mm
Access direction	1800mm side, single entry/exit
Structure	Single-cylinder dual-rail
Guide rails	100H ×2
Cylinder	Φ70-50 ×1
Power unit	4 kW
Voltage/Frequency	3-phase 200V/60Hz (Japan standard)
Pit depth	50 mm
Floor doors	Standard roller doors ×2 (1800×H2400mm)
Platform guardrails	1100mm height (both sides + cylinder side)
Enclosure	1st floor mesh enclosure, height 3700mm
Colour	Yellow-green RAL6018
Packaging	Bare, shared 20GP container with another unit

Solutions

Single-Cylinder Dual-Rail Structure – Simple & Efficient

Design approach: Single hydraulic cylinder drive + dual-rail guidance. The single cylinder simplifies the hydraulic system (no complex synchronisation required), while dual 100H rails ensure vertical stability during lifting.

Cylinder: Φ70-50 ×1, positioned on one side of the platform
Guide rails: 100H ×2, full-travel
Platform frame: J120×60×3mm rectangular tube
Platform deck: 4mm steel plate

Advantage: Simple structure, low failure rate, easy maintenance – ideal for long-term operation of overseas projects.

Ultra-Shallow Pit (50mm) – Adapting to Japanese Factory Conditions

Challenge: Japanese factories typically have concrete floors with limited excavation depth. The client required only 50mm pit depth.

Solution:

Compact cylinder base design minimises pit depth requirements
Optimised base structure allows cylinder and frame to fit within the shallow pit
Equipment installed directly at floor opening – pit only accommodates cylinder base connections

Advantage: Avoids deep excavation, significantly reduces civil work cost and installation time – adapts to Japanese factory retrofit conditions.

Japan-Standard Power Supply – 200V/60Hz

Challenge: Japan‘s industrial power standard is 3-phase 200V/60Hz – different from China‘s 380V/50Hz.

Solution:

Power unit motor customised for 3-phase 200V/60Hz
All electrical components (PLC, contactors, relays, etc.) adapted to Japan voltage/frequency
Complete electrical drawings and Japanese/English technical documentation provided

Advantage: Equipment can be connected directly to factory power on arrival – no transformer or frequency converter needed.

Compact Packaging & Sea Freight

Challenge: The equipment must share a 20GP container with another unit – packaging footprint must be minimised.

Solution:

Guide rails: 3.8m sections, shipped in two pieces, framed for protection
Lifting frame welded to the platform – minimises loose parts
No wooden crates – bare packaging with rust protection and secure lashing
Optimised packaging footprint for shared container loading

Advantage: Reduces sea freight costs and simplifies customs clearance.

Overseas Remote Approval Process

Challenge: Shaft dimensions measured by the client overseas – risk of measurement errors.

Solution:

Client provided shaft diagrams and site photos
Production drawings completed based on client data
Drawings sent to client for approval before manufacturing
Key dimensions (shaft 1940×1760mm, door 1800×H2400mm, pit 50mm) verified

Advantage: Prevents costly on-site rework due to dimension mismatches – ensures successful installation upon arrival in Japan.

Product Certificates

FAQ

Dual-cylinder would indeed be more stable, but this project’s shaft space is limited (1940×1760mm) – insufficient for dual-cylinder layout.

Dual-cylinder also requires complex synchronisation control, increasing cost and failure points.

The single-cylinder dual-rail solution ensures smooth lifting while greatly simplifying the hydraulic system – no synchronising valves, no flow dividers – lower failure rate, easier maintenance.

For 1-ton capacity and 4.6m travel, single-cylinder is fully sufficient.

Conventional freight lifts typically require 300-500mm pit depth.

This project uses a compact cylinder base design – requiring only enough space for cylinder base connections.

The cylinder body is positioned on one side of the platform, vertically installed within the shaft – not dependent on deep pit excavation.

The 50mm pit only accommodates the cylinder base for mounting and vibration absorption.

The entire hydraulic system is arranged within the shaft itself.

Japan‘s industrial power standard is 3-phase 200V/60Hz – completely different from China‘s 380V/50Hz.

Using standard Chinese equipment would require additional transformers and frequency converters on arrival – increasing cost and consuming valuable shaft space.

We customise all motors, pumps, and electrical components to 200V/60Hz at the factory.

The client can connect directly to factory power upon arrival – no conversion equipment needed.

Sharing a 20GP container requires optimised loading and secure lashing.

The guide rails are shipped in two sections (3.8m each), the lifting frame is welded to the platform to minimise loose parts – all with bare packing, rust protection, and fixed lashing.

Cross-loaded with the other unit to maximise container space.

All securing points are calculated to prevent shifting or collision during sea freight.

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