Dec. 23, 2024
Mechanical Parts & Fabrication Services
The following is a list of answers for frequently asked questions from our customers. Select questions to view the answers.
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Q1 What are the classifications of top chains? A1The top chain consists of three categories of products: plastic top chains made of plastic, stainless steel top chains made of stainless steel, and top chain accessories. For the differences between plastic top chains and stainless steel top chains, please refer to the &#;Features Chart&#; and &#;Summary Comparison of Plastic Top Chains and Stainless Steel Top Chains&#; below.
Plastic modular chain
Plastic top chain
Plastic block chain
Stainless steel top chain
Top chain accessories
&#;Top chain accessories &#;
These are convenient items for peripheral equipment for conveyors, with the optimum combination of various shapes and materials available for each application.
are lineuped as conveyor peripheral components.
&#;Features Chart &#;
Features Plastic top chain Stainless steel top chain 1 The unique softness of the plastic reduces scratches on the material being conveyed. High allowable load&#;Summary Comparison of Plastic Top Chains and Stainless Steel Top Chains &#;
Item Plastic top chain Stainless steel top chain Noise -5&#;7dB As 0 Lightness 1/3 As 1 Coefficient of friction 1/1.5&#;1/2.5 As 1 Operating temperature -20°C&#;80°C (Excluding some ) -20°C&#;400°C Allowable load 1/2 As 1 Back to questions Q2 What are the types, features and uses of plastic top chains and stainless steel top chains? A2&#;Plastic modular chain &#;
The brick-like combination of plastic module links with chain structure provides a wide belt-like conveying surface and secure drive by chain and sprocket engagement.
Depending on the application and the shape of the material to be conveyed, you can choose from &#;closed type,&#; &#;open type,&#; &#;net type,&#; etc. In addition, &#;magnet type,&#; &#;rubber type,&#; and &#;flight type&#; suitable for inclined conveyance are also available.
The conveying surface can be as wide as 50 mm, wider than that of plastic top chain or plastic block chain.
[Main purpose(s) ]
Ideal for conveying wide items, many items at once, and heavy items
&#;Plastic top chain &#;
The top plate and chain are molded together of plastic and connected by connecting pins.
The lineup also includes a format in which only the top plate is made of plastic and the chain is composed of steel. Other types are available with freely rotating rollers attached to the plate to reduce line pressure during accumulation.
Top plate width can be selected from 42.0 to 304.8 mm according to the material to be conveyed.
[Main purpose(s) ]
Ideal for loading and conveying items one by one on plates
&#;Plastic block chain &#;
Simple construction with block-shaped links connected by connecting pins.
Smaller chain pitch (9.525 to 25.4 mm) than plastic top chain allows for a smaller sprocket outer diameter.
The transfer area (dead space) can be made smaller, which allows smooth transfers. Link widths are as small as 13 to 63 mm, allowing installation in small spaces.
[Main purpose(s) ]
&#;Stainless steel top chain &#;
This top chain uses corrosion-resistant stainless steel for its main components. There are types where the top plate is made integral with the chain, and types where the two are joined together.
Generally, the maximum allowable load is higher than that of plastic top chains.
[Main purpose(s) ]
With its light weight and easy handling, plastic pins are predominant for plastic modular chains and plastic top chains. The use of plastic pins is recommended when there is exposure to water only (adhering to conveyed items from the previous process) since stainless steel pins have a shorter service life when exposed to water.
Stainless steel pins are becoming predominant for plastic block chain. Depending on the product, the allowable load is greater than with plastic pins. Stainless steel pins are recommended when there are impacts on the chain.
with plastic pin
Allowable load roughly equal to stainless steel pins (80% to 100%)
Improvements have been made to the structure of the thick plastic pins and hinges.
Long life: A combination of proprietary Tsubaki materials allows the chain to exhibit outstanding wear resistance between the pin and bushes under dry, soapy water, or wet conditions. The chain works particularly well when using water as the lubricant.
Lightweight: 15% to 25% lighter than stainless steel pin top chains. Easy to handle and effective in reducing noise and required power.
Easy disposal: As the entire chain is made of plastic, it can be disposed of as is.
Conforms to food sanitation regulations: The links and pins are manufactured from materials that are in accordance with Japan's Food Sanitation Act.
Note: Refer to Technical notes, handling of top chain, precaution of plastic pin and disconnection/connection.
2.Operating temperature up to 60&#; is allowed when plastic pin chains are used in wet conditions.
Back to questions Q5 How do I select rail material? A5
When installing plastic chains, rails are generally installed as well to guide the chain. Select the material for your rail based on your application and purpose.
General applications
Rails made of ultra-high molecular weight polyethylene (Plastic rail and plastic rails) are often used. Recommended for use in lubricated conditions.
*Be aware that more wear debris will be generated when used in unlubricated conditions.
Suppresses the generation of wear debris
PLF rail or M-rail is recommended. In addition, stainless steel (polished specification) and metal rails (hard Cr plating + buff finish) also reduce the generation of wear powder.
&#;M-rail is for dry conditions only. Do not use in lubrication or where water may splash on it.
&#;Wear dust generated on stainless steel and other metal rails will be black in color with metal powder.
Click here for details on the features of each rail
When using in high temperature conditions
Metallic rails are recommended. Use smoothly polished or hard chromium finished + buffed top finished rails.
Use at High Temperature
Recommended wearstrip material is cold-rolled stainless steel.
Secure only one end of wearstrips to allow for thermal expansion. Also, remember to leave a gap between wearstrips to allow for thermal expansion.
(Reference: Coefficient of linear expansion for 304 stainless steel is 1.8 x 10-5 mm/mm/&#;)
Example: Securing stainless steel wearstrips, and leaving space between wearstrips
Standard steel sprockets can be used for ambient temperatures below 150&#;. Special sprockets must be used at temperatures higher than 150&#;. Contact a Tsubaki representative for details.
Spacing between chains when multiple strands are used is shown below.
Take-up must be done to compensate for slack in the chain caused by thermal expansion. Take-up adjustments should be performed after reaching operating temperature. Lower temperatures only after loosening take-up.
Black wear dust will be generated. Be sure to clean on a regular basis.
Start up slowly (using inverter control) and stop slowly.
Note)
Note: Operating temperature range
When plastic rails (plastic rail, PLF rail, M-rail) are used for straight rails, please provide a gap between the rails to allow for expansion due to heat. In addition, the rails should be fixed with screws at one end.
Tongue and groove wearstrips (PR, PH), flat wearstrips
Gap between tongue and groove wearstrips &#; 3 to 5 mm
Coefficients of linear expansion
Plastic rail (P rail )&#;(PLF rail )&#;20×10-5mm/mm/&#;")%>
M plastic rail&#;9×10-5mm/mm/&#;
Note)
Mounting long straight wearstrip (extruded wearstrips such as Z, T, L, and flat) when the conveyor length is long
Gap between long straight wearstrips &#; 10 mm per meter
Mounting long straight wearstrip (extruded wearstrips such as Z, T, L, and flat) when the conveyor length is short
There are many examples, but we will introduce some typical examples.
Application Conditions Measures (Model No.)Milk carton conveying line
(Before Caser )
&#;500 ml and 1 liter packs
Conventional low-friction plastic chains from various companies have caused rattling and tipping of conveyed objects, but TTUP826-ALF prevents this problem.
&#;The TTUP type is used for the 500 ml and 1 liter paper carton lines.
Canned beer conveyor line
(Entrance of corrugated cardboard caser )
cpm line (line producing cans of beer per minute)
Replace the RSP60 standard model (white) with the RSP60-ALF to reduce line pressure.
500ml PET bottle conveyor line
(Conveyor before shrink machine )
The PET bottle line used to be dominated by 1.5-liter and 2.0-liter bottles, but nowadays, many bottles have smaller capacities, such as 500 ml.
(Due to the shift from canned to PET )
Therefore, the line must be sped up in order to maintain production volume.
(Simply put, 500 ml requires 4 times the speed of 2.0 liters )
TPH830P-ALF and TTUP826-ALF enable high-speed response with slider reduction (MAX 120m/min)
Free-flow type chains were used for 1.5-liter and 2.0-liter bottles to reduce line pressure.
However, 500 ml bottles will tip over on free-flowing items.
2-liter PET bottle conveying line
(Sorting section )
Low-friction plastic chains of various companies caused bottle misalignment and rattling during sorting, but the TPH830P and TTP826P type ALF series has solved this problem.
Cup container conveyor line
(Accumulate conveyor )
TSUBAKI Belltop BTC6--ALF is used in the section using resin belts made overseas.
Prevents container rattling with ultra-low friction and slipperiness
Back to questions Q8 What is the corrosion resistance of the top chain material? A8When selecting a chain, check from the table below that its material is adequate. This corrosion resistance can also be used to check the rail material used with the top chain.
Note that the results in this table are based on a 20°C atmosphere and do not represent the degree of guarantee. Comprehensively consider the temperature/usage conditions, etc. in actual use. The table below lists the materials (specifications) of the top plate and chain components individually, so please check them in combination.
Reagents without a concentration indication are saturated or 100% solution. Note that conditions will change when solutions are mixed together.
[Corrosion resistance to various liquids ]
Material Note) 2 Liquid nameAcetone
Oil (plant/mineral)
Alcohol (ethyl)
Ammonia water (28%)
Whiskey
Sodium chloride
Hydrochloric acid (2%)
Seawater
Hydrogen peroxide (3%)
Sodium hydroxide (caustic soda) (25%)
Gasoline
Formic acid (50%)
Formic aldehyde
Milk and butter
Citrate
Chromic acid (5%)
Acetic acid (10%)
Carbon tetrachloride
Sodium hypochlorite (sodium)(5%)
Nitric acid (5%)
Vinegar
Potassium hydroxide
Drinking water/Coffee
Soapsuds
Lactic acid
Paraffin
Beer
Fruit juice
Benzene
Water
Vegetable juice
Iodine
Sulfuric acid (5%)
Phosphoric acid (10%)
Wine
Xylene
Ozone
Peracetic acid
steel × &#; &#; &#; &#; × × × × × &#; × &#; &#; × × × &#; × × × &#; &#; &#; × &#; &#; × &#; × &#; × × × &#; &#; × ×Stainless
18-8 &#; &#; &#; &#; &#; &#; × &#; &#; &#; &#; &#; &#; &#; &#; &#; &#; &#; × &#; &#; &#; &#; &#; &#; &#; &#; &#; &#; &#; &#; × × &#; &#; &#; &#; &#; 18Cr &#; &#; &#; &#; &#; &#; × × &#; &#; &#; &#; &#; &#; &#; &#; &#; &#; × &#; × &#; &#; &#; &#; &#; &#; &#; &#; &#; &#; × × &#; &#; &#; &#; &#; Martensitic &#; &#; &#; &#; &#; &#; × × &#; &#; &#; × &#; &#; &#; &#; × &#; × &#; × &#; &#; &#; × &#; &#; &#; &#; &#; &#; × × × &#; &#; &#; &#; AS Series &#; &#; &#; &#; &#; &#; × × &#; &#; &#; &#; - &#; &#; &#; &#; &#; × &#; × &#; &#; &#; &#; &#; &#; &#; &#; &#; &#; - × &#; &#; &#; - - Plastic pinNote)
Generally, for plastic chain, the wearstrip should support the chain on the carry way, and the chain should be slack on the return way. Chain slack below the drive sprocket is especially important. Ensure there is 50 - 100mm of slack for 500 - 900mm spans (in drive operations). Tooth jumping (skipping) may occur with other slack values.
The layout of the supports for chains will vary according to the installation space available and other parameters. A typical layout is shown below. See Question No.8 for the layout of the return way of the chain.
Chain slack
Return rollers should be spaced at intervals of 500 to 900 mm to support the return way of the chain. The amount of slack in the chain between return rollers should be 50 to 100 mm. This slack prevents tooth jumping (skipping). Tooth jumping may occur when the amount of slack in these intervals falls outside of this range.
Engagement angle
The engagement angle between the drive sprocket and the chain must be greater than 150°.
Wearstrip ends
A distance equivalent to the pitch spacing of the chain must be established between the end of the wearstrip and the respective shaft centers on both the drive and driven ends. Also, the tail end of the return wearstrip on the driven side must be rounded or chamfered (sloped) to prevent catching or snagging of the chain on the wearstrip.
Height of carry-way wearstrip
Refer to Technical notes, conveyor design, rail mounting on drive/driven side.
Back to questions Q10 Return way layout for top chain and plastic block chain A10
As the most common layout, we recommend supporting your chain with return rollers. Supporting with return roller enables to you to set an applicable chain slack and absorb elongation. When using chains with float-preventive tabs, you can also support the chain through the sliding action of the tabs. However, consider using a system (such as a tensioner) to absorb chain elongation.
Other options include using a guide rails and wearstrips, using glide shoes, using guide rails only, no support on return way, etc. Be aware that not supporting the return way may cause vibration and prevent smooth operation.
The return-way layout will vary according to the type of chain, the type of goods being conveyed, the flow system and route topology, but in general, layouts will be similar to those illustrated below.
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Supported by return rollers
This is the most common and recommended layout.
A: 50 to 100 mm (during operation)
B: 500 to 900 mm
C: 400 to 600 mm
D: Less than half the outer diameter of sprocket
May vary depending on chain type and conveying conditions. To be used only as a basic guide.
&#;Refer to the technical notes in the catalog for details.
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Supported by wearstrip fitted with float-preventive tabs
Using a wearstrip to support chains fitted with float-preventive tabs eliminates sliding on the top plate surface. This is particularly applicable in situations where damage (such as scratching) to the top plate&#;s upper surface must be avoided during conveying.
A: 50 to 100 mm (during operation)
B: 500 to 900 mm
May vary depending on chain type and conveying conditions. To be used only as a basic guide.
&#;Refer to the technical notes in the catalog for details.
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Supported by serpentine-style wearstrip
Supporting the top plates only in localized areas may result in uneven wear. Install the rail in an &#;8&#;-shaped or wavelike layout so that the top chain plates are fully supported at all points. The construction should be such that extraneous matter, dirt, etc., falls through easily.
A: 50 to 100 mm (during operation)
B: 500 to 900 mm
May vary depending on chain type and conveying conditions. To be used only as a basic guide.
&#;Refer to the technical notes in the catalog for details.
[Click to enlarge ]
Supported by sliding shoes
Suitable for relatively slow-speed conveying conditions (less than 50 m/min). Generally used for accumulation chain (TTPDH-LBP) or roller tables (ST/RT).
A: 50 to 100 mm (during operation)
B: 500 to 900 mm
C: 400 to 600 mm
May vary depending on chain type and conveying conditions. To be used only as a basic guide.
&#;Refer to the technical notes in the catalog for details.
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Using guide rails only
Although this is an economical option for layouts, it has a disadvantage in that the upper surface of the top plates is susceptible to damage from sliding. Suitable for chains with relatively large back-flex radius.
A: 50 to 100 mm (during operation)
B: 500 to 900 mm
May vary depending on chain type and conveying conditions. To be used only as a basic guide.
[Click to enlarge ]
No support
This conveyor layout is normally not recommended because the tension of the return way from the weight of the chain causes chain vibration and prevents smooth operation. If this method is navoidable in the case of short conveyor lengths (less than 1.5 m), provide a take-up mechanism on the driven side or splice the chain in case the chain elongates. The wrap angle on the drive sprocket must be at least 150°.
For chains with a small sideflex radius (minimum sideflex radius (under R190)), install a corner disc when manufacturing a conveyor with a small sideflex radius. A corner disc should be installed at the center of the sideflex radius for the conveying surface and return way sides.
Curved Section Using Corner Disc on TPUSR Chain
Explanation of symbols
As shown in the figure below, for chains supported by return rollers, rollers must be installed to guide the straight portion of the return-way chain at the point where the chain enters and exits the corner.
Note: Use in a dry environment is recommended.
Back to questions Q12 What are some conveyor designs for plastic crescent chain? A12
Plastic crescent chain is designed for use in horizontal conveyors. For TORP types with rollers, guide the chain with a sprocket or wearstrip at the corners. For TORP types without rollers, use sprockets at the corners. For horizontal conveyance, a take-up mechanism must be installed to absorb elongation resulting from temperature changes or wear elongation of the conveyor. Without one, tooth jumping (skipping) can occur.
Wearstrip layout
Layout will vary depending on the installation space, but the following examples can be used for reference.
Wearstrip layout example 1 &#; Using TOSP and corner sprocket
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Wearstrip layout example 2 &#; Using TORP and corner sprocket
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Wearstrip layout example 3 &#; Using TORP and curved wearstrip
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Precautions on conveyor layout
A take-up mechanism must be installed to absorb elongation resulting from temperature changes or wear elongation of the conveyor. See example below for reference.
Back to questions Q13 How do I disconnect and assemble plastic top chain and plastic block chain? A13
Connecting pins differ by type. Disassemble, cut, or connect with a punch and hammer suited to the shape of the connecting pins. Only plastic crescent chain has a unique structure. See below for further information.
When D-pins are used (except TPUN555)
The chain can be disconnected at any link and the pin can be removed from either the left or the right.
When knurled pins are used
To disconnect, place a punch on the end of the connecting pin on the side that is not knurled and lightly tap it with a hammer to remove it. To reconnect, place a punch on the end of the connecting pin on the knurled side and lightly tap it with a hammer to insert it.(For TTPDH and TTPDH-LBP only, the knurled side is inserted from the same side even for reconnecting.)
For TN, TNU, TRU, TP-T
The pin for the connecting link is loosely fitted on the appropriate side of the outer plate. When disconnecting the chain at links other than the connecting link, remove a pair of pins parallel to one another by means of a chain vice. Once a chain is disconnected at links other than the connecting link, the link cannot be reused.
When D-pins are used (except TPUN555)
Pin insertion direction is from one direction only. Place a punch on the opposite end of the pin from the insertion direction, and tap it lightly with a hammer to remove it.
For Plastic Crescent Top Chain
1.Remove the snap cotter pin from the connecting pin, and carefully pull the offset link up and off.
2.Turn the offset link 90 degrees.
3.Remove the main link and the connecting pin from the previous link.
Note: When disconnecting, be sure not to pull the connecting pin out of the main link.
Back to questions Q14 What should I be careful of when using plastic top chain, plastic block chain, and plastic pins? A14Once removed, pins should not be reused to prevent a reduced push out force and other problems with pins falling out. The disassembling pin is colored orange so as to distinguish it from base-chain pins (colored white). Use the disassembling pin included with chain when cutting. Avoid use in wet environments where temperatures exceed 60&#;. Pin may break.
Back to questions Q15 Is forward-reverse operation possible with plastic top chain and plastic block chain? A15The direction of plastic top chains and plastic block chains is set. Forward-reverse operation is not recommended. If considering forward-reverse operation, consider using plastic modular chains.
Back to questions Q16 How to use TTP, TPF, TPS, and TPH for straight running? A16See the table below for the difference in use between TTP and TPF, TPS, and TPH for straight running.
Model TTP type TPF TPS type TPH typeAppearance
Features
Application examples
Note
See the table below for the use of TTUP and TPU for side flexing running conveyance.
Model TTUP type TPU typeAppearance
The TPU type has an float-preventive attachment that makes it possible to prevent the chain from floating up in areas where it is prone to floating up.
In the case of food products, the most important point to keep in mind is that the top surface of the plate should not slide against anything other than the product being conveyed.
With the TPU type, the return chain's float-preventive attachment is supported by the guide rail, reducing friction with anything other than the conveyed item on the top surface of the plate.
Features
Application examples
We recommend WT series, BTN5, BT6, BTC4-M, and TOD type chains with small chain pitches for reducing the size of your conveyor transfer areas. For general applications, we recommend BT8, WT, WT, WT and WT300 chains. For higher applied loads and conveying heavy objects, we recommend WT and BTH16 series chains. For eliminating gaps in connecting areas, we recommend WT, , series chains. Try magnet-embedded BTM8H and BTM8H-M chains for inclined conveyance of metal trays and parts (to prevent slipping). We recommend BTC8S for conveying cardboard boxes. For inclined conveyance, we also recommend WT series with attached flights and rubber pads.
Back to questions Q19 How do I disconnect and assemble plastic modular chain? A19The structure of each chain series differs. See below for further information.
&#;Structure and Disconnecting/Reconnecting of the BTN5, BT6, and BT8 Series
Structure of both ends of chain
A snap attachment is inserted in the link from the underside of the link at each end of the chain to prevent the pin from coming out (snap fit).
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Procedure for disconnecting and reconnecting
1) Insert a small flathead screwdriver into the gap (about 1mm) between the link hole and the snap attachment to detach the snap attachment.
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2) Use a threaded head screwdriver and screw it into the center hole (1.0mm dia.) of the pin and pull out the pin to disconnect the chain.
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3) When connecting the links of a chain, bring both ends of the chain together and insert the pin in the hole from one side. Finally, insert the snap attachment from the underside of the chain. Make certain that the snap attachment does not protrude from the bottom of the link.
&#;Disconnecting the WT/ Series
1) Insert a small flathead screwdriver or similar tool between the chain and the plug-clip on the side of the chain.
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2) Using the screwdriver as a lever, pry out and remove the plug-clip from the base chain. Work carefully so that the plug-clip does not pop out and fly off.
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3) Use a threaded head screwdriver and screw it into the center hole (1.0mm dia.) of the pin and pull out the pin to disconnect the chain.
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&#;Reconnecting the WT/ Series
1) When reconnecting the links of a chain, bring the ends of the two chains together, interlace the links, and insert the connecting pin from one side.
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2) Then re-insert the plug-clip to cover the insertion area. At this point, check the orientation of the plug-clip (make sure that the protrusion is going into the pin hole), and seat the plug-clip by pushing in until you hear it click into place.
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3) Check that the plug-clip is properly installed.
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Note: When reconnecting chain links, be sure to use the pins provided or special pins.
&#;Disconnecting the WT Series and BTM8H Series
1) Insert a small flathead screwdriver or similar tool into the hole in the plug on the side of the chain.
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2) Push the screwdriver in the direction of the arrow to slide the plug to the side.
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3) Use a threaded head screwdriver and screw it into the center hole (1.0mm dia.) of the pin and pull out the pin to disconnect the chain.
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Note: The shape for BTM8-M is different.
&#;Reconnecting the WT Series and BTM8H Series
1) When reconnecting the links of a chain, bring the ends of the two chains together, interlace the links, and insert the connecting pin from one side.
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2) Slide the plug to the side to cover the insertion area.
[Click to enlarge ]
Note: The shape for BTM8-M is different.
Note: When reconnecting chain links, be sure to use the pins provided or special pins.
&#;Disconnecting the WT Series
1) Insert a small flathead screwdriver or similar tool between the chain and the plug-clip on the side of the chain.
[Click to enlarge ]
2) Push the screwdriver in the direction of the arrow to slide the plug to the side.
[Click to enlarge ]
3) Use a threaded head screwdriver and screw it into the center hole (1.0mm dia.) of the pin and pull out the pin to disconnect the chain.
[Click to enlarge ]
&#;Reconnecting the WT Series
1) When reconnecting the links of a chain, bring the ends of the two chains together, interlace the links, and insert the connecting pin from one side.
[Click to enlarge ]
2) Slide the plug to the side to cover the insertion area.
[Click to enlarge ]
Note: When reconnecting chain links, be sure to use the pins provided or special pins.
&#;Disconnecting and Reconnecting BTC-4M and BTO8-M
1) Disconnecting
&#;Place a punch (2.5mm dia. or smaller) on the outer edge of the D-pin on the D-hole side of the link and lightly knock the punch with a hammer to remove the pin.
&#;Or, the pin can be removed using a small flathead screwdriver from the stopper side.
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2) Connecting
&#;Use the exclusively prepared D-pin (colored orange).
&#;Make certain that the D-pin is facing the correct direction and insert it into the chain link.
&#;Push by a finger or lightly knock by a hammer the stopper of the D-pin.
3) Reconnecting
&#;Do not cut the chain where a connecting D-pin (colored orange) is already inserted.
&#;Connecting D-pin
1) Use the exclusively prepared D-pin to connect the chain links.
2) The connecting D-pin is colored orange so as to distinguish it from base-chain pins (colored white).
3) One connecting D-pin is provided per chain.
&#;Structure and Disconnecting/Reconnecting of the WT and BTC8S Series
Structure of both ends of chain
A snap attachment is inserted in the link from the underside of the link at each end of the chain to prevent the pin from coming out (snap fit).
[Click to enlarge ]
Procedure for disconnecting and reconnecting
1) Insert a small flathead screwdriver into the gap (about 1mm) between the link hole and the snap attachment to detach the snap attachment.
[Click to enlarge ]
2) Use a threaded head screwdriver and screw it into the center hole (1.0mm dia.) of the pin and pull out the pin to disconnect the chain.
[Click to enlarge ]
3) When connecting the links of a chain, bring both ends of the chain together and insert the pin in the hole from one side. Finally, insert the snap attachment from the underside of the chain. Make certain that the snap attachment does not protrude from the bottom of the link.
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For wide plastic modular chains, be aware that the number of sprockets and installing positions will differ depending on chain width and tension rate. A sprocket's square or hexagonal bore will be finished larger that the corresponding shaft to handle expansion and contraction with changes in temperature and move freely laterally.
Determine Sprocket Locations
The diagrams below show the location and distance between prockets (pitch) for each type of chain. Find the percentage of maximum allowable load (maximum allowable load per 1 meter of chain width) that the tension per 1 meter of chain width F&#; derived by means of formula (2) represents. Note that the locations and pitch may change depending on chain tension rate F1.
Formula of chain tension rate F1 (%)
F&#;&#;Tension applied per 1 meter of chain width derived by formula (2) [kN (kgf)]A &#;Maximum allowable load per 1 meter of chain width with given temperature [kN (kgf)]
Wide type
1. BTN5, BTN5-A 2. WT-K, WTG-K, WT-K
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7. BT6, BTC8, BTC8-A
&#;Sprocket locations when chain tension rate (F1) is 50% or less
8. BT6, BTC8
&#;Sprocket locations when chain tension rate (F 1) greater than 50%.
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9. BTC8-A
&#;Sprocket locations when chain tension rate (F 1) greater than 50%.
10. WTK
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Mold-to-Width type
1. BTC4-500-M
2. BTO8-830-M
3. BTC8H-M/BTM8H-M 4. WTG-M300
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In general, square shafts are recommended for the drive and driven shafts used with plastic modular chain, except for special cases. Because changes in temperature will cause the chain to expand and contract, sprockets must be mounted so that they are free to move laterally in the across-the-width direction. However, to prevent meandering (snaking) of the chain, one (or two) sprocket(s) should be locked in position in the center of both the drive and driven shafts using setscrews or set-collars and hexagonal socket head cap screws. When installing the sprockets on the square shaft, the inscribed markings or identification marks should be used to orient the sprockets so that they all face the same direction and to keep the position of the teeth aligned.
&#;Phase Matching of Sprockets
Install the sprockets on the shaft in such a manner that the direction and the position of all the inscribed markings or identification marks on the sprockets are aligned.
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&#;Chain Expansion/Contraction
Plastic modular chain is made of polymer resin, and will expand and contract with changes in temperature. A rough estimate for linear chain expansion is 15×10-5 (/&#;) using 20&#; as the reference temperature. The expansion per nominal width (&#;W) is found using the following formula:
&#;W = chain nominal width × (operating ambient temperature-20) ×15×10-5
(Example) For K60 chain (1,524mm wide) used in an environment where the temperature rises from 20&#; to 60&#;:
&#;W=× (60-20) ×15×10-5 =9.1mm
&#;Locking Sprockets
The sprockets and the shaft are loosely fitted in order to absorb differences in thermal expansion between the chain and the conveyor and also installation errors of the chain and the sprockets. However, a setscrew, a hexagonal socket head cap screw, or a set-collar should be mounted on each side of a sprocket installed around the center with about 0.5mm (1.6mm for WT) clearance with the sprocket in order to prevent winding motion in the chain.
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Note: Fix the sprocket to be installed between the tab guide attachments when using a chain equipped with tab guide attachments.
&#;Chain Installation
Wind the chain onto the sprockets installed at the given intervals (refer to the &#;Chain Selection&#; section).
If the sprockets are installed at the wrong interval, the chain may run over the sprocket and break. Make certain of the center distance between the sprockets.
Back to questions Q21 How about conveyor designs of plastic modular chain? A21Generally, for plastic chain, the wearstrip should support the chain on the carry way, and the chain should be slack on the return way. Chain slack below the drive sprocket is especially important. Ensure there is 50 - 100mm of slack for 500 - 900mm spans (in drive operations). Tooth jumping (skipping) may occur with other slack values. Also, wearstrip installation on the conveying surface side will differ depending on the width of the chain, the presence of tab guide attachments, and Mold-to-Width chains.
The layout of the supports for chains will vary according to the installation space available and other parameters. A typical layout is shown below.
Note: The wearstrip of the drive sprocket section and the end of the frame should be chamfered to prevent interference.
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Chain slack
Table 1 shows the spacing L between return rollers supporting the chain on the return way below the drive sprocket. The amount of slack in the chain between return rollers should be 50 to 100 mm. This slack prevents chain teeth jumping. There is a possibility of chain teeth jumping if the amount of slack is outside this range.
Return Roller Spacing L (Units: mm) Chain Type Chain tension rate (F1) 50% or less More than 50% BT6, BT8 500&#;700 800&#; WT, BTC8S 600&#;900 WT, , , 450&#;500Note)
1.Refer to the technical notes in the catalog for Mold-to-Width chains.
2.For pasteurizers and other special conveyors, contact a Tsubaki representative.
3.Refer to the catalog technical notebook for installation of the nose bars at both ends.
Engagement angle
The engagement angle of the chain on the drive sprocket should be at least 180°. If the angle is small, teeth jumping may occur.
Wearstrip ends
A distance C equivalent to the pitch spacing of the chain should be provided between the sprocket and the end of the wearstrip. In addition, the end of the driven-side wearstrip should be rounded or chamfered to prevent the chain from snagging or catching on the wearstrip.
Location of Sprockets and Wearstrips
See illustration below.
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Wide Types (without Tab Guide Attachments)
Wearstrips should be located at equal intervals alternating with sprockets. Wearstrip spacing A is 76 mm for BTN; 76.2 mm for BT6, BT8, WT, WT, and BTC8S; 76.2 mm for WT (wearstrip width of 25 mm); 85 mm for WT and WT; and 100 mm for WT (wearstrip width of 30 mm).
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Wide Types (with Tab Guide Attachments)
(Chains with tab guide attachments: BTN5-A, WTGK, WTGTOK, WTGK, and WTGK)
Tab guide attachments (to prevent meandering) should be installed so as not to interfere with the wearstrip.
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A Dimensions Chain A(mm) Chain A(mm) WTG 44 BTC8-A 44 WTGTO 47 WTG 44 BTN5-A 44 WTG 44
Mold-to-Width Types (with Tab Guide Attachments)
Refer to the table below for guide clearance for chains with guides.Leave a clearance of around 1 mm between chains when used in multi-strand conveyors.
Chain A(mm) WTGM44 WTGTOM47 WTGM31 WTGM45 WTGM44 WTGM44 BTO8-M44 BTC8H-M44 BTM8H-M44
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As the most common layout, we recommend supporting your chain with return rollers. Supporting with return roller enables to you to set an applicable chain slack and absorb elongation. When using chains with flights, you need to ensure that the flights and rollers do not interfere with one another. Other options include using a wearstrip.
There are two methods of supporting the return way: the return roller system, and the wearstrip system. Examples are shown below.
Precautions:
1.The infeed section of the return wearstrip should be made with a large radius of at least R40.
2.Cut the chain so that the catenary section will have an appropriate amount of slack to compensate for expansion and contraction caused by temperature changes. A tensioner or similar device should be used to adjust the chain take-up.
Supported by return rollers
Conveyor side view
Refer to the technical notes for L dimensions.
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Conveyor plan view
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The center distance of the rollers (in the direction of the conveyor width) should be adjusted according to the width of the chain to be used.
Supported by serpentine-style wearstrip
Conveyor side view
Refer to the technical notes for L dimensions.
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The return way of a chain with attached flights or rubber carriers should be set up as shown below so that the flights do not interfere with rollers.
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Note: For wide chain, rollers should be positioned at 765-mm intervals.
Back to questions Q23 Is forward-reverse operation possible with plastic modular chain? A23Plastic modular chains are suitable for forward-reverse operation. See below for examples.
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Because a load 1.5 times the operating tension acts on the idler roller section in forward/reverse bottom drive, for wide machine width conveyors (greater than 1 m), either select a shaft that has adequate rigidity, or support the shaft using three-point mounting.
Back to questions Q24 I need to make a conveyor with a compact transfer area. A24Using a nose bar can help you reduce the size of your transfer areas. See further information on BTC4-M chains, which can also provide the same function.
The layout of the supports for chains will vary according to the installation space available and other parameters. A typical layout is shown below.
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Note: 1. Indicated dimensions are just for information, so finely adjust them depending on transfer conditions of the conveyed goods.
Note: 2. Even slight jerking due to the unstable shape of conveyed goods may cause trouble. Contact a Tsubaki representative when such goods have to be conveyed or chain jerking must be avoided.
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The use of WT series or BTN5 chain allows layouts in which two conveyors connect head-to-tail. The width of the dead-plate used in the space where the two conveyors abut can be as small as 20 mm.
Note)
1.The dead-plate gap (marked with &#; in illustration above) will need to be adjusted depending on the objects being conveyed.
2.Applicable chains are the WT series and BTN5 only. It should be noted that WTG cannot be adapted to this kind of layout.
For straight transfer with 10T sprockets
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For straight transfer with 18-mm-dia. shafts
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Note: The height level of the dead-plate should be finely adjusted according to transfer conditions of the conveyed goods.
Back to questions Q25 I need to eliminate items remaining when using right-angle conveyors. A25We recommend using a TOD or GTO type chain that has an integrated transfer area. See below for layout and other information.
A combination with WTGTO enables right-angle transfer of goods without using a dead-plate.
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Discharge Conveyor (WTGTO/WT)
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Note: Dimensions marked with &#; will need to be adjusted depending on the objects being conveyed.
Using Tsubaki nose bars or GTO type chains enables right-angle transfer of goods without the use of the dead-plate that is usually necessary.
Insertion Conveyor (WT/WTG/WTG)
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Note: Dimensions marked with &#; will need to be adjusted depending on the objects being conveyed.
Discharge Conveyor (WT/WTG/WTG)
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Note: Dimensions marked with &#; will need to be adjusted depending on the objects being conveyed.
Back to questions Q26 &#;Plastic modular chain &#;The sprockets that can be used with chain with float-preventive Tab. A26&#;WTT-F-W & WTT-F-W: chains with float-preventive Tab
Available Sprockets WT-SW-24T, WT-SW-32T, WT-SW-33T&#;Available because there is no interference between float-preventive Tab and the shaft.
&#;Image Diagram
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&#;Molded Sprocket
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&#;Finish Sprocket
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&#;Refer to the illustration and explanation below for the reason.
&#;WT-N-12T
Cannot be used because float-preventive Tab interferes with the key.
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&#;WT-N-18T
Cannot be used because float-preventive Tab interferes with the key, even though there is no interference between Tab and shaft.
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o, you have products that need to be moved from point A to point B. Naturally, you decide that you need a conveyor, right? Sure you could use a cart, or have people wearing their backs out toting boxes, but why not enter into the wonderful world of conveying options? Except maybe that the world of conveying is very overwhelming. It isnt just about low cost leaders here. There is so much more to consider than upfront costs.
Do you want gravity conveyor, or powered options? What about rubber or plastic belt; or steel belts? How about guiderails? Are they going to mar the product? If you accumulate, is your product going to all fall down? What style drive do you need? Do you need a VFD? Are you carrying multiple sizes of products on the same line? How fast is your changeover? How fast is your line? Can you even carry golf balls up an almost 90 degree incline? What about conveyor made from rubber bands, do they do that? Should you get a steel conveyor, or an aluminum one? Do you need adjustable height? Do they even make a conveyor for your application? Maybe most importantly, even if the conveyor works what is the system with lowest total ownership cost? So &#; Many &#; Options&#;
Let me make it simple for you. Here are five questions to ask yourself about your product when you are picking out a conveyor system. Or, you could just call us and take advantage of our free engineering and experienced staff so you dont have to worry about it, but I digress &#;
If you give some thought to those five questions and share them with your engineering partner from the get go, it can help them to help you to find the best solution for your particular application.
Make sure to check back with us next week to find out our tips for how to choose your material handling partner!
For more information, please visit Conveyor Top Chain.
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