Guide to diagnosing and correcting obstacles in a chain conveyor: chain stretching, gear fatigue, lubrication disorders and material accumulation

1. Problem description and scope

This guide is dedicated to diagnosing and correcting chain conveyor jams caused by chain stretching, gear fatigue, lubrication problems, and material build-up. Problems can occur in different types of industrial equipment, such as transport systems, packaging lines, production lines and additional conveyors. The importance of this problem is determined by the critical impact on productivity, occupational safety and economic efficiency. If not corrected, these problems could cause a line shutdown, explosion, or regulatory safety violation.

2. Safety precautions

Requirements for personal protective equipment:

• Glasses with anti-glare coating
• Gloves with steel hinges
• Pants with a high level of protection
• Boots with resistance to electric current

Power outage requirements:

• Perform blocking and labeling of all energy sources
• Install the lock on the switch and mark it
• Check the presence of stored energy reserves

Requirements for changes in the environment:

• Check for chemical liquids, high temperatures, or electrical hazards
• Avoid working in conditions of high humidity or temperature
• Use special protective equipment when working with accumulated materials

3. Necessary diagnostic tools

4. Inspection before diagnosis

5. Systematic diagnostic flow

1. Symptom: The pipeline often stops without an error message.
   1. Check: Check the clearance between the chain and gears.
      1. Result: Gap more than 1.5 mm - high probability of chain stretching.
2. Symptom: Irregularity in conveyor operation.
   1. Check: Measure the vibration of the system.
      1. Result: Vibration more than 8 mm/s - high probability of gear fatigue.
3. Symptom: Increased temperature in the system.
   1. Check: Measure the temperature of the chain and gears.
      1. Result: Temperature over 60°C — high probability of lubrication failure.
4. Symptom: Accumulation of material in gears.
   1. Check: Determine the presence of material accumulation.
      1. Result: Presence of material accumulation — high probability of mechanical interference.

6. Debug reason matrix

7. Investigation of the causes of problems

7.1 Chain stretching

Chain stretching can occur due to constant stress, insufficient lubrication or lack of regular inspection. This leads to an increase in the gap between the chain and the gears, which causes interference in the work and periodic stops of the conveyor. If this is not corrected, a complete shutdown of the system or a chip in the circuit may occur.

7.2 Gear fatigue

Gear fatigue occurs due to constant loading and insufficient lubrication. This leads to increased vibration and reduced energy transfer efficiency. If not corrected, gear wear or explosion may occur.

7.3 Violation of lubrication

Lubrication failure can occur due to the lack of regular inspection or the use of the wrong type of lubrication. This leads to increased temperature, gear fatigue and vibration. If left uncorrected, the system may overheat or fail.

7.4 Accumulation of material

Accumulation of material in the gears can occur due to insufficient cleaning or lack of regular inspection. This leads to increased vibration, reduced energy transfer efficiency and possible gear wear. Failure to correct may result in system shutdown or explosion.

8. Step-by-step repair procedures

8.1 Chain stretching

1. Measure the gap between the chain and gears
2. If the gap is more than 1.5 mm, adjust the chain
3. Use a special clamping bar for adjustment
4. Measure the clearance after adjustment
5. Check the gap again

8.2 Gear fatigue

1. Measure system vibration
2. If the vibration is more than 8 mm/s, replace the gears
3. Use high-quality gears of the appropriate type
4. Measure vibration after replacement
5. Check the vibration again

8.3 Violation of lubrication

1. Measure the circuit temperature
2. If the temperature is above 60°C, lubricate
3. Use the appropriate type of lubricant
4. Measure the temperature after lubrication
5. Check the temperature again

8.4 Accumulation of material

1. Check for accumulation of material
2. If material accumulation is detected, perform cleaning
3. Use special cleaning agents
4. Check again for material build-up
5. Perform cleaning if necessary

9. Preventive measures

10. Information on spare parts and components

For more information about spare parts, please visit our catalog: https://www.unitecd.com/e-catalog/

11. Links

• DSTU 26.3-415-2011 – Standards for industrial equipment
• EN 13151 – Requirements for chain conveyors
• ISO 10426 – Lubrication requirements
• UNITEC-D Catalog - Maintenance Master Documents