Roller chains are one of the most demanded components of various machines and mechanisms. These are used to transfer energy between shafts and reliable tools, such as chains that have high efficiency and last a long time. Due to the simplicity of manufacture, such products are produced dozens of enterprises around have been developed for the production of identical products.
The most important role in this design is assigned to the roller. It rolls over the sprocket tooth while sliding friction is replaced by rolling friction. As a result, it’s possible to maximize efficiency, and practically no energy is lost during transmission and the mechanism wears out very slowly. During the manufacturing process, the rollers undergo special processing at high temperatures – this increases their strength and durability. To reduce friction and increase transmission efficiency, the chains are additionally lubricated to prevent corrosion, protect corrosion, and protect the metal from the effects of aggressive media.
Maintenance of roller chains is vital to maximizing their life and effectiveness, particularly in construction and mining applications that are high-profile and subject to strict safety guidelines.
Here are the following factors that maximize the roller chain’s service life.
Factors to Maximize the Service Life of Roller Chains
Adhere to a Maintenance Schedule
Roller chains require regular inspection and service. Have maintenance check them regularly for proper tension, lubrication, and alignment. In a precisely sized and installed drive, roller chains can be expected to last for approximately 15,000 hours. Smaller tasks like chain adjustments and oil and filter changes should be scheduled for every three months. On the other hand, bigger tasks require cleaning, aligning, relubrication, replacing, and replacing or servicing damaged sprockets. When roller chains work in mining and construction, it’s particularly important to adhere to maintenance schedules. If you avoid regular maintenance, heavy-duty machinery can fail and cause damages.
Choose the Oil and Method of Lubrication Wisely
Roller chains are filled with grease and sealed for extended service life. Polyurethane seals prevent abrasive material from entering the inner pins and bushings, which reduces wear. In the undercarriage, the components rub against each other and wear is inevitable, lack of lubrication significantly accelerates internal wear. With proper, both sides wear out evenly. Asymmetric wear indicates a problem that needs to be identified and resolved. The pins holding the chain links together form a critical point. There are four types of roller chains, including manual lubrication, drip lubrication, disk lubrication, and stream lubrication. Choosing one will depend on the chain speed and power transmitted by the piece of equipment.
A variable that a person can’t control is the state of the soil. Rain and moisture in sandy soil directly accelerate wear. Landfills also negatively affect the track chain of the roller chains by hitting springs, lines in heavy equipment. Debris builds up between the metal-to-metal contact points and puts stress on the chain. Materials entering the undercarriage will accelerate wear, but worse if they freeze and accumulate. Therefore, regular cleaning of the undercarriage is an important daily activity.
Ensure and Right Tension and Alignment
The first thing to watch out for is chain tension. A slack chain will accelerate wear and an over-tensioned chain will put stress on adjacent components. The track with the correct tension should have a slight deflection, the ideal amplitude for which is specified by the heavy equipment manufacturer. Improper roller chain tension results in wear on bushings and sprockets. It’s necessary to check the chain tension every day, as well as when the road conditions change. Dirt in the sprocket segments alters chain tension and accelerates wear. When dirt begins to build up, release the chain tension to prevent back wear of the tip on the bushings and sprocket teeth.
Get Hardened Parts to Prevent Wear and Failure
The main drawbacks with roller chains are wear in both the chain and the sprockets for the majority of the machinery in the construction and mining industry. This is the main purpose for the chain stretching, eventually leading to failure and a full replacement of the chain and sprockets. It’s time to make changes to it. To combat this problem, you need to get solid roller chains manufactured with parts boasting high surface hardness. This significantly improves the wear resistance, extends life, and boosts performance in harsh conditions. Roller chains should be thoroughly inspected for deformed, cracked or broken parts. If any of these conditions are found, you need to replace the entire chain.
As the chain wears down, the chain pitch tends to increase, while the diameters and therefore the sprocket pitch tends to decrease. This phase shift gradually shifts the contact area between the rings and teeth towards the top of the teeth. In general, it’s believed that the contact area should be in the area defined by the angle. Sealed and lubricated track chain life is approximately 50% longer than sealed dry track chain. A sealed and lubricated track chain doesn’t only reduce bushing outer diameter and sprocket teeth wear, but also reduce noise and improves machine fuel efficiency.