Root Cause Analysis 1 min read

Root Cause Analysis of Chain Drive Stretch and Gear Wear: Measurement Methods and Prevention

Technical analysis: 0151F050100 (successor for 151F0201)

Аналіз кореневих причин витягнення ланцюгового приводу та зношування шестеренок: методи вимірювання та профілактика - UNITEC-D Industrial MRO
Витягнення ланцюга та зношування шестеренок можуть викликати аварійну зупинку. Виконання регулярної профілактики та використання сертифікованих компонентів дозволяє знизити ризики. Відвідіть UNITEC-D

Introduction: chain stretching symptom

Chain pull and gear wear are common in chain driven drives, resulting in reduced efficiency, increased repair costs and risk of accidents. In production conditions in Ukraine, this is especially critical, as production processes often require continuous operation with minimal intervention.

Component overview: DANFOSS 0151F050100

The DANFOSS 0151F050100 component is part of the chain drive responsible for transmitting revolutions from the engine to the shaft. It operates at a temperature of 20–60°C, a pressure of 0.5–2.5 bar, and a speed of up to 1200 rpm. The component complies with EN 13141-1:2007 and ISO 606:2013 standards, ensuring reliability in production conditions.

Indicators of selection at the place of occurrence of the problem

The technician found that the chain was stretched by 3-5 mm, which caused the vibration to increase to 5.5 mm/sec (the standard value is no more than 2.5 mm/sec according to ISO 10816-3:1995). Temperature measurements showed a peak of 75°C, which exceeds the permissible limit of 60°C. Measurements of the gear diameter using a micrometer showed wear of 0.3 mm, which is considered critical according to DSTU 2187:2016.

Root cause research

The research was carried out according to method 5 "Cause-effect" and the use of a debugging tree. Chain pulling was found to be due to improper installation or use of an unqualified chain. Gear wear was caused by insufficient lubrication and high loads.

The root causes have been identified

  • Incorrect chain installation (probability: 45%) - Using the wrong size chain or no stretch tracking.
  • Insufficient level of lubrication (probability: 30%) - lack of regular lubrication leads to wear of surfaces.
  • Excessive load (probability: 20%) - increased load due to incorrect operation or incorrect selection of components.
  • Unqualified repair (probability: 5%) – performing repair work without following technical recommendations.

Remedial measures

Immediate fix: Replace the chain with a new one that complies with EN 13141-1:2007 standards and check the installation using a caliper. Carry out full lubrication with oil type ISO 46.

Long-term prevention: Establish regular lubrication intervals (every 500 hours of operation), use measuring devices to control the distance between the gears, and perform visual inspections every 1000 hours.

A quick diagnostic checklist for technicians

  1. Check the distance between the gears using a caliper (standard 25-30 mm).
  2. Measure the vibration using a vibration meter (no more than 2.5 mm/sec).
  3. Check the surface temperature (no more than 60°C).
  4. Determine the lubrication level (use ISO 46 oil).
  5. Check the absence of damage on the surface of the chain.
  6. Determine the level of extension of the chain (no more than 3 mm).
  7. Make a note of the distance between the gears and save this data for later analysis.
  8. Perform a visual inspection for wear.
  9. Use a micrometer to measure the gear diameter.
  10. Check the cleanliness of the gear and the absence of dust.
  11. Determine the level of load on the drive.
  12. Measure chain tension after installation.

Prevention strategy

Regular lubrication intervals (every 500 hours of operation), use of gauges to control the distance between the gears and visual inspections every 1000 hours. The use of a vibration and temperature monitoring system (ISO 10816-3:1995) will allow detection of deviations in the early stages.

Conclusion and reference to the UNITEC-D catalog

Chain pull and gear wear are critical problems that can cause production to stop. Carrying out regular preventive maintenance and using high-quality components, such as DANFOSS 0151F050100, allows you to reduce risks and ensure the longevity of the drives.

To order and replace components, visit the UNITEC-D E-Catalog.

List of references

  • EN 13141-1:2007 – General requirements for chain transmission.
  • ISO 606:2013 – Drive chains, technical conditions.
  • DSTU 2187:2016 – Technical conditions for gears.
  • ISO 10816-3:1995 – Machine vibration measurement.
  • UNITEC-D E-Catalog - Access to certified components.

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