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Guide to Detection and Resolution of Chain Conveyor Stalling and Overload Problems

Technical analysis: Troubleshooting chain conveyor jamming and overload: chain elongation, sprocket wear, lubrication fa

Guide to Detection and Resolution of Chain Conveyor Stalling and Overload Problems

1. Problem Description and Scope

This guide is intended for detection and resolution of problems related to chain jamming and overload of chain conveyor systems in industrial conditions. Problems may occur due to increased chain length, gear wear, incorrect lubrication and material accumulation. Depending on the severity, this may be critical (system failure), medium (impact on productivity) or minor (increased noise level or energy consumption).

2. Safety Measures

Important: Before starting the diagnosis, perform the blocking/marking process to ensure power disconnection and avoid dangerous conditions. Use personal protective equipment (gloves, goggles, helmet). In case of detection of accumulation of chemical or toxic materials, perform additional measures for its removal.

3. Required diagnostic tools

Tool Model/Specification Measurement range Purpose
Multimeter Fluke 87V 0–2000 mA, 0–600 V Measurement of electrical parameters, checking of electric drive
Vibration Analyzer Keysight V93800A 0–10000 Hz, 0–200 mm/s Vibration parameter analysis for defect detection
Thermocamera FLIR T1030sc –20°C to 1200°C Detection of overheated areas and uneven lubrication
Micrometer Starrett 345 0–25 mm Gear Wear Measurement and Tooth Spacing Measurement

4. First Review: Check-list

Item Description
1 Check the condition of the chain and gears for wear or deformation
2 Record vibration values and temperature
3 Check the lubrication condition and presence of contaminants
4 Record the values of electric current and voltage
5 Test production workers on the latest changes in the system

5. Systematic Diagnostic Flow

  1. Symptom: Chain Stuck
    1. Check the pitch distance of the chain and the gap between the gears
      1. If the gap exceeds 0.5 mm: Likely cause — increase in chain length
      2. If the gap is less than 0.2 mm: Likely cause — gear wear
    2. Check the chain temperature
      1. If temperature > 60°C: Likely cause — insufficient lubrication
  2. Symptom: Overload
    1. Check vibration values
      1. If vibration > 4.5 mm/s: Likely cause — uneven loading or gear wear
    2. Check the current and voltage values
      1. If current > 110% nominal: Likely cause — overload

6. Matrix of Root Causes

Symptom Likely causes (from most likely) Diagnostic test Expected result
Stranding
  1. Chain Length Increase
  2. Gear consumption
  3. Material Accumulation
  1. Measure the gap between the chain teeth
  2. Measure the temperature of the chain
  3. Inspect the internal space of the conveyor
  1. Clearance > 0.5 mm
  2. Temperature > 60°C
  3. Presence of contaminants
Overload
  1. Uneven loading
  2. Gear wear
  3. Insufficient lubrication
  1. Measure the conveyor vibration
  2. Measure current and voltage
  1. Vibration > 4.5 mm/s
  2. Current > 110% nominal

7. Analysis of Main Causes

7.1. Chain Length Increase

Chain elongation occurs due to constant loading, incorrect lubrication, or incorrect drive operation. This leads to an increase in the gear clearance, which may result in jamming. To determine this cause, measure the clearance between the chain teeth. If it exceeds 0.5 mm, this confirms the elongation.

7.2. Gear Wear

Gears are worn out due to constant loading, incorrect lubrication or incorrect installation. Gear wear leads to an increase in the clearance between chain teeth, which may result in jamming. To determine this cause, measure the clearance between chain teeth. If it is less than 0.2 mm, this confirms wear.

7.3. Insufficient Lubrication

Insufficient lubrication leads to increased friction and overheating of the chain. This may cause jamming and overload. To determine this cause, measure the chain temperature. If it exceeds 60°C, this confirms insufficient lubrication.

7.4. Material Accumulation

Material accumulation in the chain section causes jamming. This may occur due to improper cleaning or high humidity in the environment. To determine this cause, inspect the inside of the conveyor. If contamination is found, this confirms material accumulation.

8. Step-by-step troubleshooting procedures

8.1. Chain Length Increase

  1. Measure the gap between the chain teeth
  2. Restore the chain length or replace with a new one
  3. Check the gap between gears
  4. Install a new chain with the appropriate clearance
  5. Lubricate the chain with the appropriate lubricant

8.2. Gear Consumption

  1. Measure the gap between the chain teeth
  2. Replace gears with new or restored ones
  3. Check the gap between gears
  4. Install new gears with the appropriate clearance
  5. Lubricate the gears with the appropriate lubricant

8.3. Insufficient Lubrication

  1. Measure the temperature of the chain
  2. Replace the lubricant with new or restored
  3. Check lubrication condition
  4. Install new lubrication with appropriate viscosity
  5. Measure the temperature after lubrication

8.4. Material Accumulation

  1. Inspect the internal space of the conveyor
  2. Remove material buildup
  3. Check cleaning status
  4. Install new cleaning system
  5. Measure the condition of the chain after cleaning

9. Preventive Measures

Main cause Preventive strategy Control Method Recommended interval
Chain length increase Regular check of chain length Gap Measurement Every 6 months
Gear consumption Regular gear replacement Gap Measurement Every 12 months
Insufficient lubrication Regular inspection of lubrication condition Temperature Measurement Every 3 months
Material Accumulation Regular cleaning of the internal space Internal Space Overview Every 6 months

10. Parts and Components

Component description Specification When to replace Category UNITEC-D
Chain Length 1000 mm, tooth size 5×10 mm If the gap > 0.5 mm Category 342
Gear Material: steel, size 80×80 mm If gap < 0.2 mm Category 458
Lubrication Type: synthetic, humidity 60% If temperature > 60°C Category 773
Cleaning system Material: stainless steel, power 1.5 kW When contamination is detected Category 902

Go to UNITEC-D e-catalog

11. References

  • Standards DSTU 3038-95, EN 13155, ISO 10426
  • Manufacturer manuals (for example, Siemens, Bosch)
  • Technical Service Guide UNITEC-D

List of key terms

  • Stripping
  • overload
  • chain
  • gear
  • lubrication

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