Sl No. |
Problems |
Potential Cause |
Solution |
1 |
Chain rises off from sprocket |
1. Excess chain slack. |
1. Adjust the amount of slack equally at both sides. |
2. Excess wear at the bases of sprocket teeth. |
2.Carryout hard facing of the sprockets |
||
3. Excess chain extension. |
3. Replace the elongated chain parts. |
||
4. Foreign material stuck to the bases of sprocket teeth. |
4. Remove the foreign material from the bases of the teeth. |
||
5.Reverse rotation of conveyor |
5.Avoid reverse rotation of the conveyor when chain tightened is uneven |
||
6.Uneven chain tightening of chain |
|
||
2 |
Chain separates poorly from the sprocket. |
1. Sprocket misalignment. |
1-Adjust alignment. |
2. Excess chain slack. |
2-Adjust the amount of slack. |
||
3. Excess wear at the bases of sprocket teeth. |
3-Avoid uneven tightening of the chain |
||
4.Uneven chain tightening of chain |
|
||
3 |
Wear to sides of link plats and sprockets |
1-Sprocket misalignment. |
1-Adjust alignment. |
2-Trough width is lesser than required |
2-Increase trough & runner flat width as per site conditions &
links assembled width |
||
3-Chain runner flats size is less |
|
||
4 |
Poor chain flexure |
1-Inadequate oiling/lubrication |
1-Lubricate properly, use standard lubricant during chain assy. |
2-Foreign materials between pins and bushes. |
2-Wash the chain to remove foreign materials, and then oil it. |
||
3-Corrosion between bushes. |
3-Replace with an environment resistant chain series. |
||
5 |
Abnormal noise |
1-Chain is too tight or too loose. |
1-Adjust the chain slack. |
2-Inadequate oiling. |
2-Lubricate properly. |
||
3-Excess wear of sprockets and chain. |
3-Replace chain and sprockets or get worn-out area filled & hard
face it |
||
4-Sprocket misalignment. |
4-Eliminate contact with the case. |
||
5-Slats touching the trough |
|
||
6 |
Chain vibration |
1-Excess chain slack. |
1-Adjust slack. |
2-Excess load vibration. |
2-Reduce load variation |
||
3-Excess chain speed leading to pulsation. |
3-Use guide stoppers to stop chain swaying. |
||
4-Chain flexes poorly at some points. |
4-Replace the more worn-out chain parts during overall maintenance |
||
Sprocket wear. |
|
||
5-Worn out or more clearances in rollers & bushes |
|
||
7 |
Damage to pins, bushes, rollers. |
1-Inadequate oiling. |
1-Lubricate properly. |
|
2-Jamed foreign bodies. |
2-Remove foreign bodies. |
|
Deformation of link plate holes. |
3-Corroded components. |
3-Review chain and sprocket selections. |
|
|
4-Use with greater than allowable load. |
4-Eliminate the abnormal load, and review chain and sprocket
selections |
|
|
5-Abnormal load action. |
|
|
8 |
Chain link cut or pins cut |
1-Overload operation |
1-Ensure all over load, ZSS protections are working |
2-Low breaking load of chain |
2-Select chain with higher breaking load if this problem persists |
Points to be kept in mind
1-Never weld the heat treated chains, as heat effect can reduce the strength & cause chain to break
2-Never go for electroplating of heat treated chain links, as it causes the hydrogen embrittlement failure
3-Do not use new chain on worn out sprockets
4-Gradual elongation of chain above 3% in total chain length, indicates that the chain will soon jump the sprockets
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