Guide to the Search and Resolution of Causes of Stalling and Overloading of Chain Conveyor

1. Problem Description and Area of Application

This guide is dedicated to the identification and resolution of causes of chain conveyor stalling and overload in industrial conditions. The problem may occur in different types of equipment: lifts, conveyors, dryers, processing lines. According to the severity of the impact on production, the problem is classified as critical if it causes line stoppage or unexpected costs, or as medium if it occurs periodically and does not affect the main processes.

2. Safety

Before starting the diagnosis, disconnect the power supply and lock out the mechanism.
Use safety goggles, gloves, gloves and helmet.
In case of accumulated energy or fluids (for example, oil, gas) perform additional safety measures.

3. Required diagnostic tools

4. Preliminary Overview

5. Systematic Diagnostic Scheme

1. Symptom 1: Conveyor stops under overload.
   1. Check: Presence of vibration during operation.
      1. Result: High vibration – likely cause: wear of sprocket or chain.
   2. Check: Equipment temperature.
      1. Result: Overheating – probable cause: insufficient oil level or clogging.
2. Symptom 2: Chain is stuck.
   1. Check: Chain strength.
      1. Result: Wear – probable cause: insufficient oil level or overheating.
   2. Check: Presence of contamination on the sprocket.
      1. Result: Clogging – probable cause: insufficient oil level or absence of filtration.
3. Symptom 3: Unexpected stoppage.
   1. Check: Presence of vibration anomalies.
      1. Result: High vibration level – probable cause: wear of sprocket or chain.
   2. Check: Filter presence.
      1. Result: No filter – likely cause: clogging.

6. Cause and Symptom Matrix

7. Root Cause Analysis

7.1. Wear of sprocket

Wear of the sprocket occurs due to constant friction under the influence of load and vibration. The cause may be in the incorrect selection of material or the absence of regular replacement. If not resolved, this leads to loss of engagement, causing jamming and stoppage.

Confirmation: Measure the vibration on the sprocket. If it is higher than 4.5 mm/s, this confirms wear.

Damage: Loss of grip, increased energy consumption, reduced productivity.

7.2. Chain Wear

Chain wear occurs due to prolonged use without proper lubrication and regular replacement. It causes jamming, loss of grip and high vibration.

Confirmation: Measure the elongation. If it exceeds 1.5%, this confirms wear.

Damage: Increased energy consumption, reduced productivity, increased risk of downtime.

7.3. Insufficient oil level

Insufficient oil level causes overheating of the chain and sprocket, resulting in loss of engagement and high vibration.

Confirmation: Measure the temperature. If it exceeds 60°C, this confirms insufficient oil level.

Damage: Overheating, wear, increased energy consumption, reduced productivity.

7.4. Filling

Clogging occurs due to the absence of filtration or high level of contamination. It causes reduced efficiency, loss of grip and increased costs.

Confirmation: Measure the level of contamination. If it exceeds 50%, this confirms clogging.

Damage: Reduced efficiency, increased risk of stoppage, loss of grip.

8. Step-by-step resolution procedures

8.1. Wear of sprocket

1. Measure the vibration on the sprocket.
2. If higher than 4.5 mm/s, perform replacement.
3. Use a micrometer to measure wear.
4. Replace the sprocket with a new one.
5. Check vibration after replacement.
6. Document measurements and changes.

8.2. Chain Wear

1. Measure the extension.
2. If it exceeds 1.5%, perform the replacement.
3. Use a micrometer to measure wear.
4. Replace the chain with a new one.
5. Check the extension after replacement.
6. Document measurements and changes.

8.3. Insufficient oil level

1. Measure the temperature.
2. If it exceeds 60°C, perform the replacement.
3. Measure the oil level.
4. Replace the oil with new oil.
5. Check the temperature after replacement.
6. Document measurements and changes.

8.4. Filling

1. Measure the level of contamination.
2. If it exceeds 50%, perform cleaning.
3. Use the oil-absorbing pad for analysis.
4. Clean the surfaces.
5. Install the filter if it is missing.
6. Check the level of contamination after cleaning.
7. Document measurements and changes.

9. Preventive Measures

10. Parts and Components

Please refer to our e-catalog for details on spare parts: https://www.unitecd.com/e-catalog/

11. References

• DSTU 3035-95 — Requirements for Equipment
• ISO 10426 — Chain Conveyor Requirements
• EN 13151 — Requirements for industrial equipment
• UNITEC-D Technical Manuals

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