English (UK) 
简体中文 Hey, has your equipment been making strange "thumping" noises lately? Or is it jumping out of gear and going on strike? Do not panic! Eighty percent is the roller chain in temper. Today we will chatter about how to cure it--Catch wear detection + tension adjustmentThese are the two main lifelines, and the device is immediately quiet as ever! 😉
🔍I. Wear and tear detection: three strokes to uncover the invisible killer
"Stretched chain = scrapped? Big mistake!"
Roller chain wear hidden in the hinges, hard to spot with the naked eye? Teach you three practical tips:
- see signsIf you remove the chain and look at it in the light, you'll see that the pin is worn out.Obvious steps or pits(like it's been chewed on), indicating that the wear is super 10%.
- gaugeHold it with a caliper.10 consecutive linksThe centre of the pin at both ends, the measured length exceeds the standard value of 3%?For example, the standard 10 sections of 10A type chain is 158.75mm long, if it exceeds 163.5mm - hurry up and change it!
- undisciplined: Wiggle the chain up and down with your hand.Swing over centre distance 3%(For example, if the two wheels are 1 metre apart and the sag is over 3 cm), the hinge gap is properly excessive.
⚠️lesson learnt through blood and tearsDon't mix old and new chains! If the old chain is lengthened, the new chain will be forced to "carry the thunder", and it will break in a minute. I've seen too many cases of saving a small amount of money for half a new chain, resulting in a three-day crash...
🔧Second, the tension adjustment practice: horizontal / vertical / heavy load three kinds of scenes
"Adjust the bearings too tightly to scrap, adjust them too loosely to jump the teeth and kneel!"
How do you get the tightness? Remember this.Golden Ratio: Sag = 1%-2% at centre distance(Horizontal drive). See the scene for specific operations:
| Transmission type | Adjustment tools | Key Tips | deadly minefield |
|---|---|---|---|
| Horizontal drive | Adjustable Base + Percentage Gauge | Loosen the bolt→top screw to open the sprocket→measure the sag→lock it. | The adjustment amount is not the same on both sides → The chain runs out of alignment! |
| vertical drive | Spring Tensioner Wheel | Loose edge with palletCompression force ≈ 1.5 times the weight of the chain. | Tensioner wheel mounted the other way round → Increased vibration |
| Heavy duty impact | Hydraulic automatic tensioner | Setting pressure value = effective pulling force x 1.2 (Example: 10 tonne chain set 12 tonnes) | Manual locking of bolts → overloaded chipped teeth! |
💡Tell the truth.A lot of people run straight after tuning without testing the machine-Must roll over!Correct posture: idle for 5 minutes, touch the chain temperature rise ≤ 40 ℃ (not hot), listen to the sound of uniformity without "click" noise is considered to pass.
⚙️III. Lubrication Selection Guide: Tips for Saving 30% Maintenance Fees
"All's well that ends well when buttered? You think the chain is bread!"The wrong choice of lubrication is a direct loss of life, look at this quick checklist 👇!
| Chain speed range | Recommended lubrication method | Operating Points | Examples of Applicable Scenarios |
|---|---|---|---|
| <1.5m/s | hand-brush oil | Brush into the roller-sleeve gap 1 time per shift (don't just wipe the surface!) | Agricultural Harvester Cutting Tables |
| 1.5-8m/s | Oil bath/drip oil | Oil level submerged the lowest side chain 6-12mm, summer with ISO220 oil | Factory Conveyor Line ⚙️ |
| >8m/s | pressure injection | Nozzle aligned with the small sprocket engagement point, oil pressure 0.2-0.4MPa | High-speed machine tool spindles |
🔥Exclusive data:.Graphite grease for high temperature environment! Measured in 80 ℃ above working conditions, than ordinary butterReduced wear rate of 47%(Rusted chainplates? Doesn't exist!) .
🛡️Failure prevention strategy: three major culprits to be defeated one by one
"The chain says it's bad? It's been foretold for a long time!"The 90% failure cannot escape these three points:
-
fatigue rupture::
- symptomatic: The inner side of the chain plate appearsfish-scale crack
- countermeasures:.Leave 10% margin for power(rated 10kW only 9kW)
-
hinges are worn through::
- symptomatic: Chain Pitch is too big and too small (like it's worm-eaten).
- emergency treatmentSulphurised pins with 3 times higher wear resistance.
-
glue::
- symptomatic: Roller surface withweld-like metal tumour
- masterstroke: Change when the chain speed is >8m/s.Carburised steel sprocketThe surface hardness is mentioned as HRC60+.
⚠️Older driver experience: Quarterlymagnetic particle inspection--X-ray the chain, spend $200 on inspection, save $20,000 to replace the chain!
💎And finally, a hardcore statistic.: In accordance with GB/T 18150.Tension deviation over 1mmChain wear rateDirectly doubled! But if you insist.Quarterly inspection + precise lubricationThe life expectancy easily exceeds 20,000 hours - this is not metaphysics, it's a real thing that has been measured to save 3.7 million/year by an automotive plant.
Remember, brother.Roller chain is not afraid to use it, but afraid to fool around with it.. With calipers in your hand and data in your mind, it's hard for equipment to go on strike! 🚀
