CNC machine tool chip conveyor chain conveyor line An and maintenance of the whole analysis

I. Installation and commissioning scenarios: accurate matching of equipment and working conditions

​1. Space adaptation and positioning​

• ​Precise alignment of the chip outlet: Place the chip conveyor on the side of the machine tool and adjust the height of the bracket to keep a clearance of ≤3mm between the inlet of the chain plate and the chip discharge outlet of the machine tool. If the chip outlet is higher than 1.2 metres above the ground, it is necessary to calculate the lifting angle (formula: lifting height = height of chip collector +100mm) to avoid the return of chips.
• ​Anti-vibration reinforcement: Rubber gaskets are added to the floor bolts to reduce the resonance effect of the machine tool during high-speed machining and prolong the life of the chain.

​2. Power system integration​

• ​Overload protection setting: Install a thermal relay in the motor control circuit to automatically cut off the power when the current exceeds the rated value of 15% to prevent the chain plate from jamming and causing the motor to burn out.
• ​Speed linkage commissioningThrough PLC, the conveyor speed of the chip conveyor is related to the spindle speed (e.g. the chain speed is adjusted to 2m/s when the spindle is >2000rpm), so as to realise the dynamic matching between the cutting volume and the efficiency of the chip conveyor.

II. Daily Maintenance Scenarios: Low-Cost Fail-Safe Strategies

​Critical Maintenance Actions and Cycles​

​► Special maintenance for wet processing​
Coolant pH needs to be maintained at 6.5-8.0, acidic environment (pH <6) will accelerate cold rolled steel chain plate rust. Weekly testing of water quality and the addition of rust inhibitors can reduce replacement costs 40%.

III. Troubleshooting scenarios: rapid resolution of high-frequency problems

​1. Emergency treatment of chain plate derailment​

• ​Step 1: Immediately stop the machine and manually reverse the drive wheel to retrieve the loose chain.
• ​Step 2: Check the amount of deformation of the guide rail (measured with a straightedge, deviation > 1.5mm need to be replaced)
• ​Step 3: Adjust the tensioning bolt to restore the chain sag by 3-5mm.

​2. Analysis of root causes of chip retention​

Image Code
graph TD
A[Chip build-up] --> B{direction of enquiry}
B --> C[Insufficient slope] --> C1[Support bracket added when lifting angle <30°]
B --> D[Chip pattern] --> D1[Long rolls of chips >100mm need to be fitted with a shredder.]
B --> E[Chain plate structure] --> E1[Replacement of bump type chain plate to prevent sticking][7](@ref)
Failed to generate, ask another way
​3. Triple verification of motor overheating​

Current detection: multimeter to measure whether the operating current exceeds the nameplate value
Load test: no-load operation for 10 minutes, temperature rise > 60 ℃ indicates bearing damage
Insulation test: 500V megohmmeter resistance <2MΩ need to dry the coil


IV. Intelligent upgrade scenarios: predictive maintenance implementation
​Adding sensors for early warning of malfunctions​

​Hall SensorsMonitor the real-time speed of the chain, fluctuation >15% trigger "chain plate jam" alarm.
​Temperature patches: Paste on the gearbox housing, 70 ℃ discolouration suggests lubrication failure
​Liquid Level Switch: automatic shutdown when the chip container is full, avoiding the overflow of chips to pollute the workshop (saving cleaning labour time 2h/day)


​case-based evidence: An automotive parts factory centrally monitors 32 chip conveyors via PLC, reducing fault response time from 45 minutes to 8 minutes and reducing annual maintenance costs by 180,000 RMB.


V. Life Extension Strategy: Key Component Enhancement Programme
​1. Wear-resistant modifications​

A tungsten carbide coating (0.3 mm thick) is laser-melted on the working surface of the chain plate, which resists wear from cast iron chips and increases its life to 8,000 hours.
​2. Corrosion protection​

Stainless steel chain plate needs to be pickled and passivated after welding to eliminate intergranular corrosion hazards and avoid stress fracture.
​3. Spare parts rotation mechanism​

Establishment of the "three sets of chain plates recycling" system:

Unit 1 operation → Unit 2 standby → Unit 3 maintenance

Monthly rotation equalises losses and reduces sudden downtime by 65%.


​Ultimate value closure​

Standardised installation and maintenance can increase the overall efficiency (OEE) of a chip chain conveyor line up to 95% at its core:

​Spatial Adaptation × Dynamic Maintenance × Intelligent Early Warning × Component Enhancement​

Four-dimensional synergy to achieve the goal of "zero-fault production line", a single piece of equipment to save maintenance costs of more than 24,000 yuan.