English (UK) 
简体中文 Lightweight suspension conveyor line in the workshop suddenly jammed? The track is deformed after just two years of use? Don't worry! This is eighty per cent of the installation and maintenance stepped on the pit. Today we will dismantle those masters refused to say the doorway - see the end of the conveyor line to ensure that you run more than five years without lying down!
First, the installation of the pit guide: installed right to save 100,000 maintenance fee
▶ How bad is it when the track is mounted crooked?
An auto parts factory to save installation costs to build their own track, the result is that after six months there is a "death curve" - the turning pointChain derailed month after month, losing $150,000 per shutdown. The secret is actually hidden in three numbers:
- Turning radius ≥ R500"The sharp bends are bound to throw off the workpiece.
- Track interface misalignment ≤1mmWaiting for the clanking symphony.
- Bracket level deviation <3/1000(Crooked neck track wears three times faster)
▶ Positioning method for copying homework with eyes closed
- "Field grid" on the floor.: pop up with ink lines as per drawingcrosshairsLongitudinal deviation exceeding 20mm is immediately reworked.
- Cable hammer to measure verticality: Column not plumbness control within 1/1000, excessively poor on the pad stainless steel sheet
- The Ultimate Laser Positioning Solution: High-end factory laser calibration, track straightness error ≤5mm over 6 metres length
lesson learnt through blood and tears: A certain power plant didn't do rail hardening treatment, and as a result the rails were as soft as spaghetti in the 100°C baking channel -Mandatory 16Mn steel quenching track! Ordinary steel won't last six months at high temperatures.
II. Maintenance Practical Manual: Two hours per month for a five-year life span
▶ Maintenance Interval Table (White Sticker Wall Version)
| cyclicality | must-do | Consequences of laziness |
|---|---|---|
| everyday | Check chain tightness + listen for noise before switching on the machine. | Chain collapse caused by loose screws (48-hour shutdown) |
| daily | Soft bristle brush for cleaning track dust + drops of special grease | Oil build-up leads to motor overload and burnout |
| every month | Check rail deformation + tighten all bolts | A cracked connection caused a "track collapse". |
| quarterly | Measure chain elongation (replace immediately if it exceeds 2%) | Jumping teeth slip and break precision parts |
▶ Lubrication and rust prevention life and death line
- Rejecting Oil Impersonation! It's a must.Lithium grease(-30℃~150℃ universal)
- The mystery of the location of the oil drops: ChainRoller inner ring + pin end(External grease = dust absorber)
- Exclusive programme for high-temperature workshops: Conversion to use in environments above 80°CMolybdenum disulphide high temperature greaseIt's just a matter of time before the normal grease turns to coke.
III. Failure prevention programmes: the money not spent against the loss of millions of dollars
▶ Sensor warning system (new standard in 2025)
- Vibration sensors: mounted on the drive side, with an automatic alarm for amplitudes exceeding 50 μm - two weeks' advance warning of bearing failure
- infrared thermometer: Real-time monitoring of the chain temperature, 70 ℃ yellow light = immediate shutdown for maintenance
- Intelligent TensionerAutomatic adjustment of chain tension, tension fluctuation >10% trigger protection.
▶ Overload protection 3-piece set
- Electronic Scale Interlock: Spreader over 100kg automatic power-off (a factory lost 300,000 spare parts to save this money)
- Slope Catchers: Climbing section is equipped with mechanical clips, instant locking of the rail when derailed.
- emergency stop rope: Laying along the full length of the track, with one pull for a full emergency stop (mandatory installation by statute!)
Personal view: maintenance fees are not a cost but an investment
Dried fifteen years of equipment management, seen too many factories planted - always maintenance as "spend money," in fact, theEvery $1 invested in maintenance can save $8 in repair costs + avoid 50 times the loss of production downtime!
The tougher move is.Designate the first Friday of every month as "Conveyor Line Check-Up Day."! Operate on this table:
- fig. conventional way of thinking: Take a 2-metre ruler to check the straightness (gaps >3mm are straightened immediately).
- sprockets: Sampling of 10 chain lengths (elongation exceeding 2% whole replacement)
- electronic: Multimeter to measure insulation resistance (<1MΩ must dry the line)
Remember: lightweight suspension lines are like blood in the shop, and when they're properly maintained, they naturally spurt in capacity!
The technical points of this article comprehensive GB/T 12738-2021 "Suspension Conveyor Safety Code" and the industry maintenance cases, the specific operation please follow the equipment manual.
