Root Cause Analysis 1 min read

Analysis of the causes of overheating of transmission chains: 5 common causes and diagnostic scheme

Technical analysis: 017-5003

Аналіз причин перегрівання трансмісійних ланцюгів: 5 загальних причин та діагностична схема - UNITEC-D Industrial MRO
Перегрівання трансмісійних ланцюгів DANFOSS 017-5003 може виникнути через 5 загальних причин. Використовуючи системний підхід, техніки можуть виявити причини вибуху та виконати ефективні заходи. UNITE

Introduction: A symptom of an explosion that prompts research

Overheating of transmission chains on DANFOSS 017-5003 equipment is a constant source of production problems. This results in reduced component life, increased repair costs, and loss of productivity. A circuit temperature exceeding 65 °C is considered critical and requires immediate diagnostic intervention.

Component overview: Functions, location and operating conditions

The DANFOSS 017-5003 transmission chain is used to transmit motion between two gears. It is located in a closed space of the equipment, which provides protection against dust and moisture. Operating conditions include an ambient temperature of 10 to 40 °C, an air pressure of up to 1.5 bar, and a rotation frequency of 500 to 2500 rpm.

Failure rates: What the technician sees

During the inspection, the technician detects the following symptoms:

  • Increasing the circuit temperature to 75 °C.
  • The appearance of oil deposits on the surface of the chain.
  • An increase in vibration measured in the range of 5–10 mm/s.
  • Damaged Almig resulting from cracks.
  • Changing the color of the chain to dark brown.

Investigation of the causes of the explosion: System analysis

The 5-why method and the Ishikawa diagram are used to determine the causes of the explosion. This allows for a systematic analysis of each element to establish the root cause.

Identified Causes of the Explosion: A Ranked List with Evidence Support

Below are the main causes of drive chain explosions, sorted by probability:

  1. Incorrect chain selection: Using a chain with the wrong size or load capacity. Support: Measurement of carrying capacity and compliance with DSTU 2522-2004 standards.
  2. Insufficient cooling level: A low cooling level causes an increase in temperature. Support: Temperature measurement with a thermometer with a tolerance of ±1 °C.
  3. Damaged Almigs: Cracks in Almigs lead to increased friction. Support: Vibration measurement with a vibration sensor with a tolerance of ±2 mm/s.
  4. Insufficient lubrication: Absence or insufficient level of lubrication. Support: Lubrication level measurement based on ISO 4406:1999 standards.
  5. Incorrect installation: Incorrect installation of the chain causes uneven operation. Support: Measuring the distance between the gears using a ruler with a tolerance of ±0.5 mm.

Measures taken: Immediate fixation and long-term prevention

For each of the identified reasons, the following measures are taken:

  • Incorrect selection: Replace with a suitable chain with a suitable load capacity. Long-term prevention: Periodic inspection according to the EN 13151:2005 standard.
  • Insufficient cooling level: Installation of additional cooling or adjustment of air flow. Long-term prevention: Installing a thermometer for remote measurement.
  • Damaged almigs: Replacement of almigs. Long-term prevention: Using a vibration sensor for control.
  • Insufficient lubrication: Lubrication additive or replacement of the lubricating mixture. Long-term prevention: Regular inspection of the lubrication level.
  • Incorrect installation: Check the distance between the gears and solve the unevenness. Long-term prevention: Using a ruler for accurate measurement.

Quick diagnostic check: 12 points for the technician

Below is a quick diagnostic check that a technician can perform on the tablet:

  1. Measure the circuit temperature with a thermometer (±1 °C).
  2. Check the distance between the gears (±0.5 mm).
  3. Measure the oil level with the oil dipstick.
  4. Measure chain vibration with a vibration sensor (±2 mm/s).
  5. Check the condition of the almigs for cracks.
  6. Check the system cooling level.
  7. Use a visual inspection to detect oil deposits.
  8. Check the compliance of the circuit with DSTU 2522-2004 standards.
  9. Check the compliance of the load capacity.
  10. Measure the speed of rotation of the gears.
  11. Check the condition of the seals.
  12. Run the temperature range diagnostic test.

Prevention strategy: Service intervals, condition monitoring and design improvements

To prevent the explosion of transmission chains, the following measures are taken:

  • Service intervals: Periodic check of the lubrication level every 500 hours of operation.
  • Condition monitoring: Using vibration and temperature sensors for remote measurement.
  • Design improvements: Use of improved materials and constructions to increase service life.

Conclusion: Contact UNITEC-D E-Catalog

Overheating of transmission chains can be eliminated by performing the correct diagnostic procedures and implementing preventive measures. For matching components and spare parts that meet the standards, visit the UNITEC-D E-Catalog.

Sources: Standards, manufacturing recommendations, explosion analysis handbooks

  • DSTU 2522-2004: Strength, durability and lubrication.
  • EN 13151:2005: Monitoring of working conditions.
  • ISO 4406:1999: Lubrication and measurement.
  • ISO 10816:1995: Measurement of vibration.
  • ISO 14001:2015: Environmental management system.
  • UNITEC-D E-Catalog: Spare parts that meet CE and UkrSEPRO standards.

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