Maintenance Guides 1 min read

A Guide to Diagnosing and Troubleshooting Chain Conveyor Jams and Overloads

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

Гайд з діагностики та вирішення проблем з застряганням і перевантаженням ланцюгового конвеєра - UNITEC-D Industrial MRO
Цей гайд надає методику діагностики та вирішення проблем з застряганням і перевантаженням ланцюгового конвеєра в українському виробництві. Описується діагностичний потік, матриця причин, кореневі прич

1. Description of the problem and scope

This guide is dedicated to diagnosing and solving chain conveyor jamming and overloading problems caused by chain stretching, gear wear, insufficient bonding, or material build-up. Problems can occur in various production facilities, such as packaging lines, food processing lines, power plants, and industries that use chain conveyors. Compliance with DSTU, EN, ISO standards and CE, UkrSEPRO certification is mandatory.

2. Safety during diagnosis

Power outage and blocking of the mechanism before diagnosis. Use of personal protective equipment (protective gloves, eyes, respirator).

Before starting diagnostics, perform the procedure of locking and attachment (Lockout/Tagout). Turn off power and open all mechanical units. Check the presence of protective elements and use personal protective equipment (protective gloves, eyes, respirator) when working with abrasive materials, liquids or high-temperature elements.

3. Necessary diagnostic tools

Name of the tool Model/Specification Measuring range The goal
Multimeter Fluke 289 0-2000V, 0-200mA, 0-200Ω Measurement of electrical parameters and electrical resistance
Vibration analyzer Keyence VM-9000 0-10000Hz, 0-20000μm/s Measurement of vibration characteristics
Thermal camera FLIR T1020 -20°C to 650°C Detection of overheated elements
Micrometer Mitutoyo 500-194 0-25mm Measurement of gear and chain wear
Ruler 300 mm 0-300 mm Measurement of length and wear

4. Preliminary examination before diagnosis

action Description
1 Check the working conditions: temperature, humidity, vibration
2 Note the changes in the system in the last 3 months
3 Check the history of alarms and errors
4 Take a photo or diagram of the system state

5. Systematic diagnostic flow

  1. Check if jamming or overloading occurs during conveyor operation.
  2. If a jam occurs:
    1. Check for worn chain or gears.
    2. Measure the length of the chain (norm: 0.5% of the original length).
    3. Use a micrometer to measure gear wear (standard: <0.2 mm).
    4. Check for material buildup on the chain or gears.
    5. Measure the vibration (norm: <4.5 mm/s).
  3. If an overload occurs:
    1. Check if there is insufficient adhesive.
    2. Measure the circuit temperature (norm: <60°C).
    3. Check the distance between the gears (norm: 5% of the chain size).
    4. Use a thermal camera to detect overheated elements.

6. Matrix of causes of the explosion

Symptom Causes (prevalence) Diagnostic test Expected result
Conveyor jam
  1. Stretching the chain (90%)
  2. Gear wear (7%)
  3. Accumulation of material (3%)
  1. Measure the length of the chain.
  2. Measure gear wear.
  3. Check for material availability.
  1. The length of the chain > 0.5% of the initial one.
  2. Gear wear > 0.2 mm.
  3. Availability of material on the chain.
Conveyor overload
  1. Insufficient adhesive (80%)
  2. Circuit overheating (15%)
  3. Distance between gears (5%)
  1. Measure the circuit temperature.
  2. Check the distance between the gears.
  3. Measure the level of molding.
  1. Circuit temperature > 60°C.
  2. The distance between the gears > 5% of the chain size.
  3. The level of molding < 50% of the norm.

7. Analysis of root causes

7.1. Stretching the chain

Chain stretching occurs due to constant stress, insufficient lubrication or lack of regular maintenance. If left uncorrected, this can lead to gear wear, vibration and electrical system failure. To confirm, use a micrometer to measure the length of the chain. If the length is tracked by 0.5% or more, stretching occurs.

7.2. Gear wear

Gear wear occurs due to high vibration, improper installation, or insufficient lubrication. If left uncorrected, this can lead to conveyor failure, machinery failure, and explosion. Use a micrometer to measure wear to confirm. If the wear exceeds 0.2 mm, wear occurs.

7.3. Insufficient lubrication

Insufficient lubrication occurs due to lack of regular maintenance, damage to the lubrication systems or the consumption of lubricating fluid. If left uncorrected, this can lead to overheating, vibrational deviations, and component wear. To confirm, use a thermal camera to measure the temperature of the circuit. If the temperature exceeds 60°C, overheating occurs.

7.4. Accumulation of material

Accumulation of material occurs due to lack of regular cleaning, lack of filters or explosions in the system. If not corrected, this can lead to jamming, electrical system failure, and conveyor failure. Use visual inspection and wear measurements to confirm. If a build-up is detected on the chain or gears, there is a build-up of material.

8. Step-by-step solution procedures

8.1. Stretching the chain

  1. Measure the current chain length.
  2. If the length exceeds 0.5% of the initial length, adjust the chain.
  3. Set the chain to the correct length or replace it.
  4. Check the distance between the gears.
  5. Perform vibration and temperature measurements.

8.2. Gear wear

  1. Measure gear wear.
  2. If wear exceeds 0.2 mm, perform correction.
  3. Install new gears or perform a rebuild.
  4. Check the distance between the gears.
  5. Perform vibration and temperature measurements.

8.3. Insufficient lubrication

  1. Measure the circuit temperature.
  2. If the temperature exceeds 60°C, lubricate.
  3. Lubricate the chain in the appropriate amount (from 20 to 30 g per meter).
  4. Check the lubrication system.
  5. Perform vibration and temperature measurements.

8.4. Accumulation of material

  1. Perform a visual inspection of the chain and gears.
  2. If build-up is found, clean.
  3. Use hydraulic tools or sponges to remove build-up.
  4. Check the distance between the gears.
  5. Perform vibration and temperature measurements.

9. Preventive measures

The root cause Prevention strategy Control method Recommended interval
Stretching the chain Regular measurement of chain length Micrometer monthly
Gear wear Regular check of gear wear Micrometer monthly
Insufficient lubrication Regular lubrication of the chain Thermal camera monthly
Accumulation of material Regular cleaning of the chain and gears Visual inspection a week

10. Spare parts and components

Description Specification When to replace UNITEC-D category
Conveyor chain Length 20 m, diameter 12 mm After wear and tear 1110-1120
Gear Material: steel, diameter 50 mm After wear and tear 1110-1120
Lubricating fluid Type: synthetic, content 1500 ml After wear and tear 1110-1120
Hydraulic tool Model: UK-150, power 1.5 kW After wear and tear 1110-1120
Sponge Material: nylon, size 200 mm After wear and tear 1110-1120

For parts and components details, please visit: https://www.unitecd.com/e-catalog/

11. Links

  • DSTU, EN, ISO standards for maintenance
  • Manufacturer's instructions for the chain conveyor
  • Additional materials on solving problems with the conveyor in UNITEC

Examples of use

  • A system with a vibration analyzer for measuring vibration
  • Thermal camera for detection of overheated elements
  • Micrometer for measuring wear
  • Multimeter for measuring electrical parameters

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