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• How to calculate Number of Chain Length, Links and Lock type for sprockets?

• How to Calculate Roller Pitch for Chain Driven Live Roller Conveyors

Chain driven live roller conveyors are used to move the products such as carton boxes, plastic crates, totes etc at a controlled speeds higher or lower whatever it may be. Chain driven live roller conveyors are beneficial because there is positive engagement between chain and chain teeth and gives excellent power transmission for heavy duty loads also. It is often a complaint that chain driven roller conveyors have more noise. But the noise comes from improper engagement of chain and sprocket. This results because of mis-calculations of roller pitch. So lets understand it. Most of us have done chain tensioning to the cycle in their childhood. We do it, when the chain gets removed from the sprocket frequently, or their is chain noise. When you adjust the chain tensioning of the bicycle chain, you are actually managing the distance between the chain teeth, so that it engages properly. We do that by reducing the distance between two sprockets or by increasing the distance between two sprockets. This needs to be done periodically because the bolts gets loosened or chain elongates after long working. Now lets get to some basics. Any chain have pitch. If a chain is 4" chain, it means that when a sprocket moves by 1 teeth, the chain will move by 4". By the way 4" = 4inch = 4x25.4 = 101.6mm Below are the sprocket pitches which are generally used for conveyor rollers. 3/8" = 3/8 inch = 3/8 x 25.4 = 9.52mm 1/2" = 1/2 inch = 1/2 x 25.4 = 12.7mm 5/8" = 5/8 inch = 5/8 x 25.4 = 15.87mm For Roller Conveyors, chain is transferred from one roller to other. So there is no scope for tensioning as it will disturb other pair. So how we do that. The Best way is to maintain the optimum distance while design only and there is no need to tensioning. Lets consider an example. You have to carry a carton box of 400mm length, width 350mm and weight 50kg. For any product to be stable, there has to be 4 rollers below the product any time. So 400mm / 4nos = 100mm. The pitch should be 100mm. Considering pitch 100mm, the load on each roller will be 50kg / 4nos = 12.5kg The load capacity of each roller should be 12.5kg Check the roller capacity chart. Here we take roller dia 50.8 which comes with 1/2" x 14z sprocket. The pitch of roller is 1/2inch i.e. = 12.7mm Now 12.7 x 8 = 101.6mm So ideally the pitch should be 101.6mm If we keep that pitch 101.6mm, it will become difficult to put chain lock and join the chain. Hence to ease out the efforts, you can reduce the roller pitch and keep as 101.3 or 101 All chains come with Half Lock and full lock. so if we use half lock, we can also use odd pitches. e.g. 12.7 x 7.5 = 95.25mm. Please refer below video where a conveyor is running at 50meters/min

• 10 advantages & benefits of conveyor systems

• 5 ways to adjust conveyor belt tension and tracking of belt

Belt Tracking is often an issue faced by conveyor manufacturers and users. Maintenance people are called frequently for belt tracking problems in production areas. Below are the steps by which should be followed while tracking the belt With the advancement in technology, there are other ways to avoid and minimize the belt tracking issues. It can be avoided by following ways Coating of the Drive Roller Crowning of the Drive Roller knurling of the Drive Rollers Centre Guide for the belts. Below you shall find the procedure to track the belt. One should understand the science behind belt untracking. Conveyor belt is cut square ( rectangle ) while joining. When the belt is trying to come to its origin, i.e. squareness it leaves its position and it gets out of the track. The elements of the belt conveyors need properly at 90degree to each other such as the support frame, the drive & driven rollers, support rollers. When we are adjusting the belt tension, we are only trying to maintain the squareness of the belt. One should follow each step carefully with the technical understanding of the same. You should provide sufficient time for the belt to take its position, after each adjustment. Do make small changes, allow the belt to move, observe the position and decide the next action. Steps to Track your Conveyor Belt and adjust tension Check runout or concentricity of the drive/driven roller Runout or concentricity of the drive/driven rollers is the most known cause of belt getting untrack. Check the drive & Driven Rollers position if it is exactly at the right angle to the belt. Basically, if you join the centre lines a perfect square should be formed. Conveyor support structure may be welded or aluminium profile welded, in any case, it is necessary that it forms a perfect square. Check the Support Rollers are exactly at the right angle to the belt top.  The support rollers may force to change the position. Check if any foreign material is stuck below the belt e.g. some carton box cut pieces, metal debris, electrical wires, screws or Nuts. Check if the belt properly cut... a perfect Square Cut. Do share your likes and comments on this post to enable us to improve.

• What is difference between Bulk Conveying and Unit Handling Conveyors?

• A Guide on how to calculate ROI of your Conveyor Equipment?

• Uneven loads on Roller Conveyors

Uneven loads on roller conveyors are difficuilt to be carried unless a roller conveyor is specially designed for that. While design of a Gravity Roller Conveyor or Powered Roller Conveyor, we use 3 or more rollers to make the product more stable. But in case of uneven loads it won't work. We have to support the uneven portion by 3 rollers so that it wont topple. The even portion may get stuck in the gap between the rollers. To avoid this, we have to reduce the roller pitch to minimum possible according to the size of the uneven portion. In the image below, the carton box is having concentric load at the arrow portion. This will make the box behave as shown.

• How to Calculate Load Carrying Capacity of Conveyor Rollers?

Load carrying capacity of conveyor rollers is crucial for the conveyor system. Under designing the system may land you in trouble damaging the system. Over designing the conveyor system might go over budgeting. Calculating load on conveyor roller is simple arithmetic and very easy. Assume that you have to design a Gravity Roller Conveyor System for carton box conveying. Weight of the carton box is 50kg Length of the box is 400mm Width of the box is 300mm Lets Calculate width of the rollers = width of the carton box + 50mm So Roller length is 350mm Now we have to decide how many rollers will be below the carton box? For a component, Box, product to be stable 3nos of rollers are required below it, assuming equal distribution of weight in the product. So 400/3 = 133mm will be roller pitch. ( Roller Pitch is always considered as Centre to Centre) . We will consider roller pitch as 100mm on a safer side. so there will be 4 rollers below the box at any time. It means 50kg weight will be distributed on 4nos of rollers. Calculating further we shall get 12.5kg Finally we need 12.5kg of load carrying capacity roller over a length of 350mm. ​In Spite of all above calculations and load Capacity Chart, one should note that above the capacities at the chart are indicative only. The load carrying capacity is dependent on lot of other factors like product weight concentricity, impact load generated on the rollers while loading the component on conveyor.

• What is Load Carrying Capacity of Conveyor Rollers & Selection of Rollers?