1.

Chain Basics
1.1 What is a Chain?

1.1.1 Basic Structure of Power Transmission Chain

1.1.2 Basic Structure of Small Pitch Conveyor Chain

1.1.3 Basic Structure of Large Pitch Conveyor Chain-Engineering Class

1.1.4 Functions of Chains Parts

1.2 Advantages and Disadvantages of Chain for Power Transmission and Conveyors

1.2.1 Power Transmission Uses

1.2.2 Conveyance Uses

1.3 Sprockets

1.1 What is a Chain?

A chain is a reliable machine component, which transmits power by means of tensile
forces, and is used primarily for power transmission and conveyance systems. The
function and uses of chain are similar to a belt. There are many kinds of chain. It is
convenient to sort types of chain by either material of composition or method of
construction.

We can sort chains into five types:

1. Cast iron chain

2. Cast steel chain
3. Forged chain
4. Steel chain
5. Plastic chain

Demand for the first three chain types is now decreasing; they are only used in some
special situations. For example, cast iron chain is part of water-treatment
equipment; forged chain is used in overhead conveyors for automobile factories.

In this book, we are going to focus on the latter two: "steel chain," especially the
type called "roller chain," which makes up the largest share of chains being
produced, and "plastic chain." For the most part, we will refer to "roller chain" simply
as "chain."

NOTE: Roller chain is a chain that has an inner plate, outer plate, pin, bushing, and roller.
 In the following section of this book, we will sort chains according to their uses,
which can be broadly divided into six types:

1. Power transmission chain

2. Small pitch conveyor chain
3. Precision conveyor chain
4. Top chain
5. Free flow chain
6. Large pitch conveyor chain

The first one is used for power transmission, the other five are used for conveyance.
In the Applications section of this book, we will describe the uses and features of
each chain type by following the above classification.

In the following section, we will explain the composition of power transmission chain,
small pitch chain, and large pitch conveyor chain. Because there are special features
in the composition of precision conveyor chain, top chain, and free flow chain, check
the appropriate pages in the Applications section about these features.

1.1.1 Basic Structure of Power Transmission Chain

1.1.2 Basic Structure of Small Pitch Conveyor Chain

1.1.3 Basic Structure of Large Pitch Conveyor Chain-Engineering Class

1.1.4 Functions of Chains Parts

1.1.1 Basic Structure of Power Transmission Chain

A typical configuration for RS60-type chain is shown in Figure 1.1.
 Figure 1.1 The Basic Components of Transmission Chain

Connecting Link

This is the ordinary type of connecting link. The pin and link plate are slip fit in the
connecting link for ease of assembly. This type of connecting link is 20 percent lower in
fatigue strength than the chain itself. There are also some special connecting links which
have the same strength as the chain itself. (See Figure 1.2.)

Tap Fit Connecting Link

In this link, the pin and the tap fit connecting link plate are press fit. It has fatigue
strength almost equal to that of the chain itself. (See Figure 1.2.)

Offset Link

An offset link is used when an odd number of chain links is required. It is 35 percent
lower in fatigue strength than the chain itself. The pin and two plates are slip fit. There
is also a two-pitch offset link available that has a fatigue strength as great as the chain
itself. (See Figure 1.3.)
 Figure 1.2 Standard Connecting Link (top) and Tap Fit Connecting Link (bottom)

Figure 1.3 Offset Link

1.1.2 Basic Structure of Small Pitch Conveyor Chain

The basic structure is the same as that of power transmission chain. Figure
1.4 shows a single pitch conveyor chain. The double pitch type in Figure 1.5has an
outer plate and an inner plate of the same height, but often has a roller with a larger
diameter. Usually, an attachment is used with this chain.

Figure 1.4 Single Pitch Conveyor Chain with K-1 Attachment

 Figure 1.5 Basic Structure of Double Pitch Conveyor Chain with A-

1.1.3 Basic Structure of Large Pitch Conveyor Chain-

Engineering Class
Large pitch conveyor chain has the same basic structure as double pitch conveyor
chain (Figure 1.5), but there are some differences. Large pitch conveyor chain
(Figure 1.6) has a headed pin, sometimes a flanged roller (F-roller), and usually does
not use a riveted pin. Large pitch conveyor chain is also called engineering class
chain.

1.1.4 Functions of Chain Parts

Plate

The plate is the component that bears the tension placed on the chain. Usually this is
a repeated loading, sometimes accompanied by shock. Therefore, the plate must
have not only great static tensile strength, but also must hold up to the dynamic
forces of load and shock. Furthermore, the plate must meet environmental
resistance requirements (for example, corrosion, abrasion, etc.).
 Figure 1.6 Basic Structure of Large Pitch Conveyor Chain

Pin

The pin is subject to shearing and bending forces transmitted by the plate. At the
same time, it forms a load-bearing part, together with the bushing, when the chain
flexes during sprocket engagement. Therefore, the pin needs high tensile and shear
strength, resistance to bending, and also must have sufficient endurance against
shock and wear.

Bushing

The bushing is subject to shearing and bending stresses transmitted by the plate and
roller, and also gets shock loads when the chain engages the sprocket.

In addition, when the chain articulates, the inner surface forms a load-bearing part
together with the pin. The outer surface also forms a load-bearing part with the
roller's inner surface when the roller rotates on the rail or engages the sprocket.
Therefore, it must have great tensile strength against shearing and be resistant to
dynamic shock and wear.

Roller

The roller is subject to impact load as it strikes the sprocket teeth during the chain
engagement with the sprocket. After engagement, the roller changes its point of
contact and balance. It is held between the sprocket teeth and bushing, and moves
on the tooth face while receiving a compression load.

Furthermore, the roller's inner surface constitutes a bearing part together with the
bushing's outer surface when the roller rotates on the rail. Therefore, it must be
resistant to wear and still have strength against shock, fatigue, and compression.
 Cotter Pin, Spring Clip, T-Pin

These are the parts that prevent the outer plate from falling off the pin at the point
of connection. They may wear out during high-speed operation, therefore, for this
application, these parts require heat treatment.

1.2 Advantages and Disadvantages of Chain for Power

Transmission and Conveyors
1.2.1 Power Transmission Uses

1.2.2 Conveyance Uses

1.2.1 Power Transmission Uses

Power transmission machines use either chains, gears, or belts. Table 1.1provides a
comparison of typical applications.

Usually, chain is an economical part of power transmission machines for low speeds
and large loads. However, it is also possible to use chain in high-speed conditions
like automobile engine camshaft drives. This is accomplished by devising a method
of operation and lubrication.

Basically, there are lower limits of fatigue strength in the gear and the chain, but not
in the belt. Furthermore, if a gear tooth breaks, the gear will stop at the next tooth.
Therefore, the order is gear > chain > belt in the aspect of reliability.

In most cases:

1. An increase in gear noise indicates that the end of the service life is near.
2. You will know that the chain is almost at the end of its life by wear elongation or an
increase in vibration caused by wear elongation.
3. It is difficult to detect toothed-belt life without stopping the machine and inspecting the
belt carefully.

It is possible to decrease gear noise by adjusting the gears precisely or by adapting

the drive to a helical or double helical gear. Both of these are expensive, and thrust
load may occur with the use of helical gears.

Chain is more suitable to long-term continuous running and power transmission with
limited torque fluctuation. Gears are more fit to reversing or intermittent drives.
 The greater the shaft center distance, the more practical the use of chain and belt,
rather than gears.

Generally, under the same transmission conditions, the cost of toothed belts and
pulleys is much higher than the cost of chains and sprockets.

See the following features and points of notice about roller chain transmission.

Features of Chain Drives:

1. Speed reduction/increase of up to seven to one can be easily accommodated.

2. Chain can accommodate long shaft-center distances (less than 4 m), and is more
versatile.
3. It is possible to use chain with multiple shafts or drives with both sides of the chain.
4. Standardization of chains under the American National Standards Institute (ANSI), the
International Standardization Organization (ISO), and the Japanese Industrial Standards
(JIS) allow ease of selection.
5. It is easy to cut and connect chains.
6. The sprocket diameter for a chain system may be smaller than a belt pulley, while
transmitting the same torque.
7. Sprockets are subject to less wear than gears because sprockets distribute the loading
over their many teeth.

Points of Notice:

1. Chain has a speed variation, called chordal action, which is caused by the polygonal
effect of the sprockets.
2. Chain needs lubrication.
3. Chain wears and elongates.
4. Chain is weak when subjected to loads from the side. It needs proper alignment.

1.2.2 Conveyance Uses

Conveyor systems use either chains, belts, or rollers, depending on the application. The
general guidelines for suitability are shown in Table 1.2, and discussed in Basics Section
1.2.1. Belt conveyors are most suitable for large-volume movement of bulk materials.
Except for this situation, chains, belts, and rollers are generally difficult to compare in
terms of capacity, speed, or distance of conveyance of unit materials.
 1.3 Sprockets
The chain converts rotational power to pulling power, or pulling power to rotational
power, by engaging with the sprocket.

The sprocket looks like a gear but differs in three important ways:

1. Sprockets have many engaging teeth; gears usually have only one or two.
2. The teeth of a gear touch and slip against each other; there is basically no slippage in a
sprocket.
3. The shape of the teeth are different in gears and sprockets.

2. Chain Dynamics
A study of phenomena that occur during chain use.

 2.1 Chains under Tension

o 2.1.1 Elastic Stretch, Plastic Deformation, and Breakage
o 2.1.2 Engagement with Sprockets
 2.2 Chain Drive in Action
o 2.2.1 Chordal Action
o 2.2.2 Repeated Load Tension, Fatigue Failure
o 2.2.3 Transmission Capability of Drive Chains
 2.2.3.1 Difference Between Linear Tension and Wrapping
 2.2.3.2 Effect of Normal Chain Wear on Fatigue Strength
 2.2.3.3 Strength Differences Between Chain and the Connecting Links and Offset Links
o 2.2.4 Wear of Working Parts
o 2.2.5 Noise and Vibration
 2.3 Characteristic Phenomena in Conveyor Chain
o 2.3.1 Coefficient of Friction
o 2.3.2 Dynamic Tension of Starting and Stopping
o 2.3.3 Wear Between Rollers and Bushings
o 2.3.4 Strength of Attachments
o 2.3.5 Stick Slip
o 2.3.6 Relative Differences in Chain's Total Length
o 2.3.7 Take-Up
2.2.3.2 Effect of Normal Chain Wear on Fatigue
Strength
When a chain is operating, the outer surface of the pin and inner surface of the
bushing rub against one another, wearing little by little. (Proper lubrication reduces
the amount of wear but does not eliminate it.)

The problem is the wear of the pin. As the surface of the pin is reduced, the rigidity
of the pin decreases and eventually fatigue failure may result. The question is how
much wear is acceptable and at what point should you be concerned.

Testing shows that when wear elongation is less than or equal to 1.5 percent for
transmission chain, or less than or equal to 2 percent for conveyor chain, there is
almost no risk of fatigue failure.

NOTE: This replacement limit applies to situations in which every pin and bushing wears
equally. If one part is subject to greater wear, the system should be examined and
repaired. Chains should be replaced at the same time.

In practical terms, the most important consequence of deterioration is a decrease in

the fatigue strength by environmental factors. This problem will be discussed
in Basics Section 5.4.

2.2.3.3 Strength Differences Between Chain and the

Connecting Links and Offset Links
The individual connecting links and offset links have lower fatigue strength than the
chain itself. Therefore, you have to consider the strength-decrease ratio shown
in Table 2.1. The strength-decrease ratio differs from manufacturer to manufacturer,
so it is important to get specific information from each manufacturer.

If you use chain with loads that are almost the same as the maximum allowable
load, you should avoid using offset links. Use tap fit connecting links, which are
stronger than standard connecting links. In some cases, you can order chains in an
endless configuration (see NOTE on next page).
 NOTE: Endless configuration: Manufacturers create connecting components that are as
strong as the chain's other parts by riveting or other factory processes. The chain is
assembled and delivered as an endless configuration.

The transmission-ability graph, which is sometimes called a "tent curve" because of

its shape, includes the result of the three points covered above. This graph is an
important tool when making chain decisions.Figure 2.19 illustrates the concept of a
tent curve.

In Figure 2.19, Line O-A is decided according to the chain's allowable tension, which
includes the fatigue strength of the connecting or offset links, as well as the centrifugal
force in high-speed rotation. Line B-C is decided by breakage limit of the bushing and roller.
In this kind of breakage of the bushing and roller, there is no fatigue limit as there is with
the link plates. Therefore, it is shown within 15,000 hours of strength-in-limited-duration.
Line D-E is decided by the bearing function of the pin and the bushing.

The range defined within these three lines (O-A, B-C, and D-E) is the usable range.
When the chain is used at low speeds, it is limited by line O-A, the fatigue limit. The
conditions of the tent curve shown are:

a. Two-shaft wrapping transmission with 100 links of chain.

b. Duration of 15,000 hours work.
c. Under the Additional Operating Conditions (1 through 5 shown below).

Additional Operating Conditions

1. The chain operates in an indoor environment of −10°C to 60°C, and there is no abrasive
dust.
2. There are no effects from corrosive gas or high humidity.
3. The two driving shafts are parallel with each other and adjusted properly.
4. Lubrication is applied as recommended in the catalog.
5. The transmission is subject to only small fluctuations in load.
6. 2.2.4 Wear of Working Parts
In Basics Section 2.2.3.2, we discussed the effects of pin wear. When a chain is
operating, the outer surface of the pin and inner surface of the bushing rub against
one another, wearing little by little.

When a chain is operating, obviously other parts are also moving and wearing. For
example, the outer surface of the bushing and inner surface of the roller move
against one another. In the case of transmission chain, the roller and bushing wear is
less than that of the pin and the inner surface of the bushing because the chance of
rubbing is generally smaller. Also, it is easier to apply lubrication between the
bushing and roller.

The progress of pin-bushing wear is shown in Figure 2.20, in which the horizontal
axis is the working hours and the vertical axis is the wear elongation (percent of
chain length).

In Figure 2.20, O-A is called "initial wear." At first the wear progresses rapidly, but
its ratio is less than 0.1 percent and usually it will cease within 20 hours of
continuous operation. A-B is "normal wear." Its progress is slow. B-C is "extreme
wear." The limit of "allowable wear" (the end of its useful life) will be reached during
this stage (1.5 to 2.0 percent).

The solid line reflects a case of using chain with working parts that were lubricated in
the factory, but were not lubricated again. If you lubricate regularly, the pin and the
bushing continue to exhibit normal wear (reflected by the dotted line), and
eventually run out their useful life.

If you remove all the lubricants with solvents, the wear progresses along a nearly
straight line, and the life of the chain is shortened. This is shown by the dashed line.

The factors that affect chain wear are very complicated. There are many
considerations, such as lubrication, assembly accuracy, condition of produced parts,
and the method of producing parts; therefore, wear value can't be greatly improved
by merely changing one factor.
 In transmission chain, JIS B 1801-1990 regulates the surface hardness of the pin,
the bushing, and the roller (as shown in Table 2.2) to meet the multiple
requirements for wear resistance and shock resistance.

2.2.5 Noise and Vibration

When the chain engages the sprockets, it will definitely make noise (Figure 2.21).
This is caused by several factors:

1. The chain roller strikes the sprocket tooth bottom.

2. There is space between the roller and the bushing; the roller makes noise by its elastic vibration
(in the case of thin rollers, like S-roller).
3. Sprockets vibrate.
4. The fluid held between each part (usually air or lubrication oil) makes shock sounds.

Take for example, an RS80 transmission roller chain and a sprocket with 16 teeth
operating at a speed of 123 rpm. (The chain speed is 50 m/min.) In this case, the
noise at a point 30 cm from the sprocket will be: with no lubrication, 65 dB (A); with
lubrication, 57 dB (A).

According to the data given above, the noise made by the chain engaging the
sprocket can be predicted. Please contact the manufacturer.
 There are some steps you can take to lessen the noise level.

a. Decrease striking energy:

o Use a sprocket with many teeth. This reduces the impact velocity while maintaining the same chain
speed.
o Operate the chain at slower speeds.
o Use smaller chain to decrease the chain's weight.
b. Buffer the effects of the impacting parts:
o Lubricate at the bottom of the sprocket tooth and the gap between the bushing and the roller.
o Use specially engineered plastic rollers. (This will also decrease transmission capability. There is
virtually no decrease in sound if you change to an engineered plastic sprocket.)

If we compare noise from chains and sprockets with other transmission machine
parts like belt and pulley or toothed belt and pulley, we find:

a. Belt noise is less than the other two. Compared to a flat belt, a toothed belt makes a high
frequency noise during high speed.
b. Usually, chain transmission is smoother than gear transmission. The chain also differs in that there
is no increase in noise level as it wears and elongates during use.

2.3 Characteristic Phenomena in Conveyor Chain

Until now, we have primarily been explaining matters that apply specifically to power
transmission chains. However, there are some different problems that occur when
using conveyor chain.

 2.3.1 Coefficient of Friction

 2.3.2 Dynamic Tension of Starting and Stopping
 2.3.3 Wear Between Rollers and Bushings
 2.3.4 Strength of Attachments
 2.3.5 Stick Slip
 2.3.6 Relative Differences in Chain's Total Length
 2.3.7 Take-Up

2.3.1 Coefficient of Friction

The tension of transmission chain is calculated by dividing the transmitted power
(indicated as kW or horsepower) by the chain speed and multiplying by an adequate
coefficient. But in a fixed-speed, horizontal conveyor, tension is decided by those
factors shown below:

1. The coefficient of friction between the chain and the rail when conveyed objects are placed on the
chain.
2. The coefficient of friction between conveyed objects and the rail when conveyed objects are held
on the rail and pushed by the chain.
 NOTE: There are two types of tension: the first occurs when conveyed objects are moving
at a fixed speed, and the second is inertial effects that occur when starting and stopping
the machine. We will only talk about the former in this section, and the latter in Basics
Section 2.3.2.

The tension (T) in a horizontal conveyor, like that in Figure 2.22, is basically
calculated by this formula:

T = M1 × g × f1 × 1.1 + M1 × g × f2 + M2 × g × f3

Where:

 T = total chain tension

 M1 = weight of the chain, etc.
 M2 = weight of conveyed objects
 f1 = coefficient of friction when chain, etc., are returning
 f2 = coefficient of friction when chain, etc., are conveying
 f3 = coefficient of friction when conveyed objects are moving
 g = gravitational constant
 1.1 = sprocket losses due to directional changes of the chain
NOTE: "chain, etc.," in the above formula includes chain and the parts moving with the
chain, such as attachments and slats.

In this formula, a coefficient of friction is multiplied by every term in the equation.

Therefore, if the coefficient of friction is high, the tension increases and larger chain
is required. Also, the necessary motor power, which is calculated as tension × speed
× coefficient, increases. A more powerful motor is needed when the coefficient of
friction is high.

Reduce the coefficient of friction and you can reduce the tension, too. This allows you
to choose a more economical chain and motor, and decrease the initial and running
costs for conveyor equipment.

The chain's coefficient of friction differs by type of chain, by material, and by type of
roller; it is shown in the manufacturer's catalog. To illustrate this concept, two
examples are included. The coefficient of friction for different types of top chain and
guide rails is shown in Table 2.3. The coefficient of friction when large R-roller chain
rotates on rails (rail material: steel) is shown in Table 2.4.
 Technology can help you reduce the coefficient of friction. Some of the newest chains
(for example, low-friction top chain, engineered plastic roller chain, and bearing
roller chain) can achieve low coefficients of friction without lubrication. Other chains
would have to be lubricated to achieve these coefficients. In some instances, these
new chains achieve dramatically lower coefficients of friction. That means you can
save maintenance time, money, and energy at your facility.

2.3.2 Dynamic Tension of Starting and Stopping

Conveyor chain accelerates when it changes from stop mode to operational speeds,
and decelerates when it changes from operational speeds to stop modes. Therefore,
a dynamic tension resulting from inertia affects the conveyor chain, and it is added
to "the tension produced when conveyed objects are moving at fixed speed," which
is discussed in Basics Section 2.3.1. You must consider dynamic tension caused by
inertia, especially in the following cases:

1. Starting and stopping chains frequently, such as intermittent use with indexing equipment.
2. Starting and stopping in very short time spans.
3. When chains in motion suddenly receive stationary objects to convey.

The dynamic tension by inertia is calculated with this formula:

T1 = M × α = M × (dv / dt)

Where:

 M = total weight of conveying apparatus, including chain, attachments, product, etc., (kg)
 α = maximum acceleration (m/s2)
 dv = change in speed (m/s)
 dt = time in which speed change occurs (s)

For example:

 M = 5,000 kg, the total weight of chain, attachment, product, etc.

 f = 0.12, the dynamic coefficient of friction
 T = 5,000 × 9.8 × 0.12 = 5,880 N

This assumes the conveyor is operating at constant speed. But when the chain
starts, if the speed is increased to 20 m/min. in 0.2 seconds, then:

dv = 20/60 = 0.33 m/s

dt = 0.2 s

T1 = 5,000 × (0.33 / 0.2) = 8,250 N

Maximum tension = T + T1 = 14,130 N

If the chain is accelerated frequently in this manner, then select chains using T + T1.

2.3.3 Wear Between Rollers and Bushings

During the operation of conveyor chains, rollers receive some additional forces,
which are shown in Figure 2.23 and listed below:

1. The weight of conveyed objects when they are put directly on the chain.
2. The reaction forces when pushing conveyed objects with a dog.
3. Directional variation tension when the rail is set in a curved path.

These forces cause wear between rollers and bushings.

Some manufacturers publish an "allowable roller load"—a value at which the wear
rate of the roller is comparatively slow. For steel rollers, it is the value with
lubrication. For engineered plastic rollers and bearing rollers, the values shown are
without lubrication. Sometimes, engineered plastic rollers may be affected by speed.
Please check the catalogs.

If foreign objects, including conveyed objects, get into the working parts of the
chain, the catalog values are no longer applicable, even if you are using lubrication.
There are many conveyed objects that work as lubricants; therefore, it is hard to
generalize about the allowable roller loads when there are any foreign objects that
might get into the working parts. Furthermore, the loads on the rollers (as shown in
points 1 through 3 above), are also applicable to the side rollers and to the resulting
wear of pins and side rollers. Make sure you consider these factors when setting up a
conveyor system.

2.3.4 Strength of Attachments

Bending and twisting forces can affect the attachments. For the A attachment, which
is a common type, the allowable load calculation indicated in catalogs is based on the
bending strength.

When a tall fixture is added onto the attachment, you must study the strength of the
entire configuration. When the attachment is subject to forces other than those
explained, you also must calculate the twisting forces. If the attachment receives
bending forces at the same time, make sure to combine the bending forces with the
twisting forces.

When calculating the strength of attachments such as A-type, K-type, SA-type, and
SK-type, which are extensions of a standard steel chain's plate, use the values
shown below as their ultimate tensile strength, and choose a proper safety factor.

Nonheat-treated plate: 490 MPa (50 kgf/mm2)

Heat-treated plate: 1,078 MPa (110 kgf/mm2)
 2.3.5 Stick Slip
When using an extra-long conveyor system (more than 15 m) and slow chain speed
(less than 10 m/min.), you may notice longitudinal vibration in the line, which is
called stick slip, or jerking.

The basis for this phenomenon can be seen in Figure 2.24. Here the coefficient of
friction is plotted against the speed of the chain. When operating a long conveyor at
slow speeds, the coefficient of friction for sliding surfaces (in top chains, between top
plates and rails; in R-rollers, between the outer surface of the bushing and inner
surface of the roller) decreases as speed increases. This causes the chain to jerk or
stick slip.

Usually, you can't solve this problem by adding lubrication or by increasing the
number of sprocket teeth. There are, however, things you can do to prevent or
reduce stick slip:

1. Increase chain speed.

Figure 2.24 How Chain Speed Impacts the Friction Coefficient

2. Eliminate or decrease the decline in the coefficient of friction by using a bearing roller
(please consult with manufacturer if the speed is less than 2 m/min.), or use a special
kind of lubrication oil (Tsubaki special oil, or others).
3. Increase chain rigidity (AE). A is the chain's section area, and E is Young's modulus. To
increase AE, use a larger chain. If there are several chains with the same allowable
tension, choose the one with the thicker plate.
4. Separate the conveyor into sections and reduce the length of each machine.

If stick slip continues to be a problem, consult the equipment manufacturer.

2.3.6 Relative Differences in Chain's Total Length
If you want to achieve a precise positioning of more than two chain lines to be used
in parallel, you can order "matched and tagged" chain. Generally, if the conveyor
chains are made in the same lots, the relative differences in length will vary only
slightly. Table 2.5 shows the amount of variation for several types of chain chosen at
random from the same production run.

If your specific application requires less variation than those listed in Table 2.5,
consider matched and tagged chains as an effective solution.

2.3.7 Take-Up
Conveyor chains need proper tension, which is why take-up is added to a system.
You have to position take-up where the chain's tension will be minimal. If you can
remove two links from the chain, the adjusting length of take-up is:

L = chain pitch + spare length

If you can't remove links from the chain, use this formula:

L = length of machine × 0.02 + spare length

In this formula, 0.02 represents the allowable wear value (2 percent). There are two
portions of the spare length: one is the maximum and minimum range of variation in
length for new chains; the other portion is the length to loosen the chain's
connecting link when the chain's total length has been set as tight as possible. For
example: the machine length is 10 m, the length for maximum and minimum range
of variation is 0.25 percent, assuming the length needed to connect chain is 25 mm,
then:

L = 10,000 × (0.02 + 0.0025) + 25 = 225 + 25 = 250 (mm)

If the chain expands and contracts with temperature, the system needs some means
to absorb it. When you use a chain in a high-temperature environment or to convey
high-temperature objects, the chain becomes hotter and the length increases at
about the same ratio as its coefficient of linear expansion. When the temperature is
between 0° and 300°C, and 1 m of chain is heated by a value of 100°C, the chain
elongates by about 1 mm. If you want to allow for this elongation with take-up, you
must be careful about the following points or the chain may fail:
 In the case of chain temperature increase, adjust take-up after the temperature increase.
 In the case of chain temperature decrease, adjust take-up before the decrease.

In the case of chain temperature change, the take-up should be designed to absorb
the elongation or the contraction of the chain.

If you don't drive the chain in reverse, it is more convenient to design a catenary
section and collect the elongation in that part. In that case, it is also beneficial to
design a take-up. Figure 2.25 shows an example of a design with catenary and take-
up.

It is very annoying to continuously adjust take-up. Sometimes it is possible to use

self-adjusting take-ups by hanging a weight or using a hydraulic power cylinder
instead of adjusting the take-up. However, the chain receives additional tension by
doing this (sometimes the motor capacity is also influenced), so don't forget to check
the chain strength as well as the motor capacity.

Another point about take-up is that if you drive the chain in reverse while carrying
objects, the take-up receives the load as if it were a driving part. In this situation,
you must select and design take-up with consideration for its strength.

3. Public Standards of Chains

Because chain is widely used throughout the world, there are both international and
domestic standards to guarantee their interchangeability and functions. Table 3.1
shows the primary standards.
 4. How to Select Chains
In this chapter, we outline the selection process. To choose the right chain, follow
the step-by-step procedure for the type of line you're running. The first thing you
must determine is the type of application: power transmission or conveyor. The
selection process differs for the two applications; see Basics Sections 4.1 and 4.2.

In addition to the procedures described in this book, chain manufacturers usually

provide comprehensive selection charts in their catalogs; refer to the manufacturer's
catalog for detailed information.

 4.1 Transmission Chain Selection

o 4.1.1 Chain Selection Factors
o 4.1.2 Coefficient Used in Selection
o 4.1.3 Drive Chain Selection (General Selection)
o 4.1.4 Power Transmission Chain Selection for Slow Speeds
o 4.1.5 Hanging Transmission Chain Selection
 4.2 Conveyor Chain Selection
o 4.2.1 Check of Conditions for Selection
o 4.2.2 Conveyor Type Selection (General Selection)
o 4.2.3 Selection of Chain Type and Specification
o 4.2.4 Points of Notice About Roller Type
o 4.2.5 Chain Pitch Decision
o 4.2.6 Deciding the Number of Sprocket Teeth
o 4.2.7 Deciding the Attachment Type
o 4.2.8 Calculation of Tension
 4.2.8.1 Horizontal Conveyor
 4.2.8.2 Free Flow Conveyor
o 4.2.9 Allowable Load of Roller and Standard A Attachment
 4.3 Selection Example

4.1 Transmission Chain Selection

There are four main uses for transmission chains: power transmission, hanging
transmission, shuttle traction, and pin-gear driving.

1. Power transmission. The most frequent application, power transmission involves an endless chain
wrapped on two sprockets. There are two ways to select chains for this use.

For general applications, you can select by power transmission capability (tent curve). This is shown
in Figure 4.1.

For slow-speed operation, you can make an economical selection using the maximum allowable tension.
Use this method when chain speed is less than 50 m/min. and starting frequency is less than five
times/day (Figure 4.2).
2. Hanging transmission. This design is increasing in popularity. It is used, for example, in
parking garage elevators. Sprockets rotate, and conveyed objects can be lifted or
suspended at the end of chains. (Figure 4.3).
3. Shuttle traction. (Figure 4.4).
4. Pin-gear drive. In this design, the chains are laid straight or in a large diameter circle and
are driven with special tooth form sprockets. This design is more economical than using
gears (Figure 4.5).

In this book, we will focus on items 1 and 2. Consult your manufacturer's catalog
for information on items 3 and 4.
 4.1.1 Chain Selection Factors
You must consider the following conditions:

1. Type of application.
2. Shock load.
3. Source of power: motor type; rated power (kW); moment of inertia, I (kg • m2); rated torque at
driving speed; starting torque; and stopping torque.
4. Drive sprocket rpm and shaft diameter.
5. Driven sprocket rpm and shaft diameter.
6. Center distance between sprockets.
7. Noise constraints.
8. Lubrication (possible or not).

4.1.2 Coefficients Used in Selection

1. Multiple strand factor
In multiple strand power transmission chains, the loading is unequal across the width of the chain,
therefore, the transmission capability is not a direct multiple of the number of chains. You must
use a "multiple strand factor," which is shown in Table 4.1, to determine the correct value.
2. Service factor, Ks
The chain transmission capability is reduced if there are frequent or severe load fluctuations. You
must apply the appropriate factor based on the type of machine or motors (Table 4.2).
3. Chain speed coefficient, Kv; sprocket tooth coefficient, Kc
Adjust the transmission capability according to the chain speed and number of teeth in the small
sprocket (Figure 4.6). The sprocket coefficient is labeled Kc.
4. Impact coefficient, K
This coefficient (Figure 4.7) is based on the inertia ratio of the driving machine and driven
machine (ratio of I, ratio of GD2) and the amount of play in transmission equipment. When the
inertia ratio is less than 0.2 or greater than 10, use the value of 0.2 or 10, respectively.
5. Unbalanced load coefficient; Ku
When you use two or four chains in a hanging application or shuttle traction setup, the tension of
each chain is not equal. This must be accounted for by using the coefficient found in Table 4.3.
The example assumes an unbalanced load ratio between two chains of 60/40 (percent) [i.e., 60 +
40 = 100 percent].
 4.1.3 Drive Chain Selection (General Selection)
A suitable chain selection may be made according to the flow chart Figure 4.8.
EXAMPLE: Select a transmission chain for the conditions shown inFigure 4.9.

Type of Application: Drive of Belt Conveyor

Source of Power: Electric Motor 7.5 kW
Drive Shaft: Diameter 66 mm. 50 rpm
Driven Shaft: Diameter 94 mm. 20 rpm
Center Distance of Shafts: 1,500 mm
Starting Frequency: 4 times/day
Type of Impact: Some Impact
Reducer Ratio: 1/30

 Step 1. Confirm the operating conditions.

 Step 2. Determine the service factor Ks as shown in Table 4.2. In this example, the service factor
is Ks = 1.3.
 Step 3. Calculate the corrected design power kW = 1.3 3 7.5 = 9.75 kW.
 Step 4. Consult the selection table (Figure 4.10). For n = 50 rpm and corrected power = 9.75 kW,
you should initially select RS140 chain and a 15-tooth drive sprocket. These are not the final
selections. See manufacturer's catalog for additional information.

 Step 4a. Calculate the size of the driven sprocket. Number of teeth in driven sprocket = 15 3
(50/20) = 37.5. Therefore, select a 38-tooth driven sprocket.
 Step 4b. Confirm that the chain meets the power requirements. According to the power
transmission tables in the catalog, an RS140 chain with a 15-tooth sprocket is capable of
transmitting 11.3 kW. Because 11.3 kW is greater than the design power of 9.75 kW, it is
acceptable.
 Step 5. Confirm that you can set a 15-tooth sprocket and a 38-tooth sprocket within the 1,500-
mm center distance and still maintain clearance. The maximum hub bores of each sprocket are 89
and 110, respectively. Therefore, these may be used.
 Step 6. Calculate L, the number of chain pitches.

C = center distance ÷ chain pitch

C = 1,500 ÷ 44.45 = 33.746 (sprocket center distance, in pitches)

L = (N + N′) / 2 + 2C + ((N − N′) / 6.28)2 / C = (38 + 15) / 2 + 2 × 33.746 + ((38 − 15) / 6.28)2 / 33.746

= 94.39 links

Because you can't have fractions of links, choose the next highest even number. In this example,
you would use 96 pitches. The center distance of the sprockets will then be 1,536 mm.

 Step 7. Check the catalog and decide the appropriate type of lubrication (manual or drip).
 4.1.4 Power Transmission Chain Selection for Slow
Speeds
This selection procedure is based on the maximum allowable tension, which is used
when the chain speed is less than 50 m/min., and the starting frequency is less than
5 times/day. The selection is done following the flow chart in Figure 4.11.

EXAMPLE: Recalculate the previous example from Basics Section 4.1.3based upon
the selection for slow speed.

 Step 1. Tentatively select RS120 chain, which is one size smaller than RS140, and a 15-tooth
sprocket. Then calculate the chain speed.
V = PNn / 1,000 = (38.1 × 15 × 50)/ 1,000 = 28.6 m/min. < 50
According to this speed and starting frequency, case selection for slow speed may be used.
 Step 2. From the rated power of the motor, calculate the tension Fm on the chain.
Fm = 60 × kW / V = 60 × 7.5 / 28.6 = 15.7 kN
 Step 3. Service factor Ks = 1.3, Chain speed coefficient Kv = 1.06
(from the chain speed 28.6 m/min.).
 Step 4. Sprocket tooth coefficient Kc = 1.27 (from 15-tooth sprocket).
 Step 5. Calculate the design chain tension F′m.
F′m = Fm × 1.3 × 1.06 × 1.27 = 27.5 kN
 Step 6. Decide on the chain size.
 According to the catalog, the maximum allowable load of RS120 is 30.4 kN. Because this
value is higher than the chain design tension determined in Step 5, RS120 may be used in
this application.

Select the number of teeth in the large sprocket according to the speed ratio, using
the same procedure as in the general selection.

Confirm the chain and the sprocket: driving sprocket is RS120-15T (maximum hub
bore is 80 mm, and the shaft diameter is 66 mm; therefore, this may be used), and
driven sprocket is RS120-38T (maximum hub bore is not shown in catalogs).
Therefore, consult with the manufacturer and determine that the 38-tooth sprocket
will accommodate a 94-mm shaft.

 Step 7. Calculate the chain length (number of links).

C = 1,500 ÷ 38.10 = 39.37

L = (N + N′) / 2 + 2C + ((N − N′) / 6.28)2 / C = (38 + 15) / 2 + 2 × 39.37 + ((38 − 15) / 6.28) 2 / 39.37

= 105.58 links

Therefore, use 106 links. Center distance = 1,508 mm.

 Step 8. Check the manufacturer's catalog to determine the necessary type of lubrication (manual
or drip).
 As you see, this selection allows you to choose a smaller and more economical chain
than the general selection. But, at the same time, consider these facts:

 Do not use offset links or normal connecting links for slow speeds. Use tap fit connecting links,
which have a tight interference fit. If you want to use offset links or normal connecting links,
check the strength derating shown in Basics Section 2.2.3 and recalculate.
 Cast-iron sprockets are not strong enough for slow speeds. Therefore, use SS400, S35C, S45C,
etc.
 Use a hardened-tooth sprocket for the high-speed sprocket.
 The bearing pressure on the chain will be very high, so lubricate the chain well.

4.1.5 Hanging Transmission Chain Selection

Calculate the chain tension on both the load side and the driving side, and select a
chain with a suitable maximum allowable tension to satisfy the requirements. The
points of notice are shown below.

 If there are any laws or guidelines for chain selection, check and calculate accordingly. Make sure
to follow the manufacturer's selections, and select the safer one of the two selections.
 The chain speed should be less than 50 m/min. If it is more than 50 m/min., consult the
manufacturer.
 Use tap fit connecting links that have a tight interference fit.
When you want to use normal connecting links or offset links, you must apply the appropriate
derating value (Basics Section 2.2.3) to the chain strength.
 Lubricate the chain joints as much as possible after you reduce the loads.
Lubrication is also required at terminal connections, etc.
 Make sure to follow proper safety procedures, including:
a. Be sure that no one is under the suspended objects.
b. Install a reliable safety guard to avoid damage in the event of chain failure.
c. Examine chains regularly, and replace when necessary.

Figure 4.12 shows some common examples of hanging use. Selection is done
according to the flow chart in Figure 4.13.
 EXAMPLE: You are planning to use a hanging transmission machine like the one
shown in Figure 4.14. Determine if you can use SUPER120 for hanging and
SUPER100 for the drive chain. The power source is a 3.7-kW motor (with brake). The
motor shaft rotational speed is 1,500 rpm.

 Step 1. Check the motor characteristics.

Rated torque: Tn = 0.038 kN • m
Starting torque: Ts = 0.083 kN • m
Braking torque: Tb = 0.096 kN • m
Motor moment of inertia: Im = 0.015 kN • m
 Step 2. Calculate the chain tension based on load.
The chain tension Fw = M = 3,000 × 9.80665 × 10-3 = 29.4 kN
Service factor Ks = 1.3 (with some shock)
The chain speed coefficient Kv = 1.02 (from the chain speed 6.2 m/min.)
Coefficient for number of sprocket teeth Kc = 1.28 (14-tooth sprocket)
Coefficient of unbalanced load Ku = 0.6 (two sets of chains)
Determine the chain design tension
F′w = Fw × Ks × Kv × Kc × Ku
= 29.4 × 1.3 × 1.02 × 1.28 × 0.6 = 29.9 kN
 Step 3. Calculate the chain tension based on the motor loading. Calculate moment of inertia of
motor shaft.

I = M × (V / 2πn1)2 = 3,000 × (6.2 / (2 × π × 1,500))2 = 0.0013 kg • m2

 Moment of inertia of motor Im = 0.015 kg • m2
Inertia ratio R = I / Im = 0.087

When there is no play in the system, the coefficient of shock K = 0.23

(Figure 4.7). The chain tension from the starting torque:
Fms = Ts × i × (30 / 14) × 1,000 / (d / 2)
= 0.083 × 60 × (30 / 14) × 1,000 / (171.22 / 2) = 124.7 kN

The chain tension calculated from the breaking torque:

Fmb = Tb × i × (30 / 14) × 1,000 × 1.2 / (d / 2)
= 0.096 × 60 × (30 / 14) × 1,000 × 1.2 / (171.22 / 2) = 173.0 kN

Use the larger value (in this case it is Fmb) to calculate chain tension.
F′mb = Fmb × Kv × Kc × Ku × K
= 173.0 × 1.02 × 1.28 × 0.6 × 0.23 = 31.2 kN

 Step 4. Calculate the chain tension from motor acceleration and deceleration.

Working torque Tm = (Ts + Tb) / 2 = (0.083 + 0.096) / 2 = 0.0895 kN • m

Load torque TL = (M × d) / (2 × 1,000 × i) × (g / 1,000)

= (3,000 × 171.22) / (2 × 1,000 × 60 × (30 / 14)) × (g / 1,000) = 0.02 kN • m

Motor acceleration time ts = ((Im + Il) × n1) / (375 × (Tm − Tl)) × (g / 1,000) × 4

= ((0.015 + 0.00130) × 1,500) / (375 × (0.0895 − 0.02)) × (g / 1,000) × 4 = 0.037s

Motor deceleration time tb = ((Im + Il) × n1) / (375 × (Tm + Tl)) × (g / 1,000) × 4

= ((0.015 + 0.00130) × 1,500) / (375 × (0.0895 + 0.02)) × (g / 1,000) × 4 = 0.023s

Because tb is smaller than ts, the chain tension due to motor deceleration Fb is greater than that of the
acceleration.

Fb = (M × V) / (tb × 60 × 1,000) + Fw = (3,000 × 6.2) / (0.023 × 60 × 1,000) + 29.4 = 42.9 kN

Therefore, the chain design tension:

F′b = Fb × Kv × Kc × Ku = 42.9 × 1.02 × 1.28 × 0.6 = 33.6 kN

When comparing the calculated chain tensions in Steps 2, 3, and 4, note that F′b in Step 4 is the greatest.
In this tension, Ku is already counted. Comparing F′b with the maximum allowable tension of SUPER 120
chain, F′b < 39.2 kN. Therefore, this chain may be selected.

The example shown above is for chain in hanging drives. The maximum tension on the wrapping
transmission chains is:

F′b × d / d′ = 33.6 × 171.22 / 303.75 = 18.9 kN

This value is less than the maximum allowable tension of SUPER 100 chain, which is 30.4 kN. Therefore, this
chain is acceptable.

Other Important Considerations

NOTE 1: If there are laws or regulations for chain selection, you must take them into
account. For example, if the safety guideline says, "Safety factor must be greater
than 10:1 compared with the minimum tensile strength," then you should design the
equipment as shown above, and consider the following:
For hanging drive chain:
Minimum tensile strength
= M × g × Ku × 10 = 3,000 × (9.80665 × 10-3) × 0.6 × 10 = 176.5 kN

But the minimum tensile strength of SUPER 120 chain is only 124.6 kN, which is not
enough to meet this requirement. Instead, select SUPER 140 chain (213 kN).

Wrapping transmission chain requires more than 99.5 kN of minimum tensile

strength, therefore you may select SUPER 100 chain (111 kN).

Regulations are not always safer than manufacturer's suggested selection procedure.
Choose the safest system possible.

NOTE 2: If a load greater than the motor braking torque very 48 occasionally
occurs, the chains will be subjected to the following loads:

Wrapping transmission chain:

Fd = (0.096 × 1,000 × 60 × 2) / 142.68 × 0.6 = 48.4 kN

Hanging drive chain:

48.4 × (303.75 / 171.22) = 85.9 kN

To avoid chain plastic deformation, the minimum tensile strength must be more than
twice these loads (see Basics Section 2.1.1), therefore, you should select SUPER 100
chain and SUPER 160 chain.
 4.2 Conveyor Chain Selection
There are five types of conveyor chains:

a. Small pitch conveyor chain.

b. Precision conveyor chain.
c. Top chain.
d. Free flow chain.
e. Large pitch conveyor chain.
 To select any of these chains, use the procedure outlined in the flow chart (Figure
4.15). Chain tension is calculated based on the load size.

In these five types, because often the objects conveyed on small pitch conveyor
chains, precision conveyor chains, and top chains are light, sometimes you don't
have to check "allowable roller load." Also, attachments are not usually installed on
top chains and free flow chains, therefore, you don't need to check the attachment
allowable load.

 4.2.1 Check of Conditions for Selection

 4.2.2 Conveyor Type Selection (General Selection)
 4.2.3 Selection of Chain Type and Specification
 4.2.4 Points of Notice About Roller Type
 4.2.5 Chain Pitch Decision
 4.2.6 Deciding the Number of Sprocket Teeth
 4.2.7 Deciding the Attachment Type
 4.2.8 Calculation of Tension
o 4.2.8.1 Horizontal Conveyor
o 4.2.8.2 Free Flow Conveyor
 4.2.9 Allowable Load of Roller and Standard A Attachment

4.2.1 Check of Conditions for Selection

You should check the items shown below:

1. Application conditions: application environment, indoor or outdoor, temperature, existence of

foreign objects.
2. Conveyed objects: type (unit materials, bulk materials), abrasive, corrosive, temperature (high or
low), dimension (for unit material), weight (unit material kg/unit; bulk material kg/m3).
3. Maximum conveyance volume (unit materials, kg/conveyor length; bulk materials, tons/hour).
4. Method of conveyance: pushing with dog attachments, conveyed objects placed directly on the
chains, etc.
5. Length of the conveyor, shaft center distance, vertical rise, general layout.
6. The chain speed (m/min.).
7. Number of the chain strands, interval length.
8. The chain pitch, attachment spacing and type.
9. The number of sprocket teeth, or pitch diameter.
10. Working hours (hours/day, hours/year).
11. Lubrication.
12. Motor: AC or DC, kW × number of motors.
13. Noise: If there is any noise constraint, use a larger number of sprocket teeth. Consult the
manufacturer.
 Some Additional Thoughts

You can make your decision on point 4 after reviewing the points in Basics Section
4.2.2, Conveyor Type Selection. Make sure to follow the procedure carefully.

Point 7 is more difficult to determine than it looks; the materials being conveyed
impact the decision. Because the chain sizes and configuration may change as the
design is developed, you must consider this point carefully. Consider these
examples:

 If you convey fixed-sized pallets directly on chain, you usually need two sets of chains. But if the
pallet is not rigid enough, you should include a third chain between the two outer chains.
 If you convey different-sized pipes or similar items directly on chain, you must consider the
shortest length so that at least two chains are supporting the product on line, and determine the
appropriate number of chains so that the chains are equally loaded.

Points 8, 9, and 12 may be revised as you proceed with the selection process since
the chain sizes are usually determined by roller load, so make a preliminary selection
first.

4.2.2 Conveyor Type Selection

According to conveyed object type (unit or bulk materials), typical chain conveyor
types are sorted as shown on the next page. Therefore, you should choose the
formation from among these.

In Figure 4.16, the available chain types are abbreviated below. These abbreviations
mean:

 RF: Double pitch roller chain, RF conveyor chain. Plastic roller and plastic sleeve chain may be
used to convey unit materials.
 RS: RS attachment chain
 RF-B: RF bearing roller conveyor chain
 RFN: Bearing bush chain
 RFD: Deep link chain
 VR: DOUBLE PLUS® chain
 TR: Top roller chain
 SR: Outboard roller chain
 TP: Top chain
 NF: Block chain (bar and pin)
 NFX: Block chain—flow conveyor type
See Applications section for details of these chains.
 4.2.3 Selection of Chain Type and Specification
A conveyor design can use a variety of chains, depending on the type of operation,
conditions, and material conveyed. Here we present a few points of notice about
selection.

1. Consider RF, RS, or TP chain first. Typical applications are outlined in Table 4.4.
2. If there are no special temperature or environment concerns, and if the chain is not subject to
rough usage, you can use plastic roller or RF-B chain. This reduces the amount of friction.
3. When you require accurate stopping location or must avoid chain elongation, select RFN.
4. NF is suitable for rough use and for conveyance of high-temperature objects.

4.2.4 Points of Notice About Roller Type

Figure 4.17 shows the roller types and ways of guiding used in conveyor chains.

1. First of all, consider if an R-roller will meet the operating conditions.

2. An S-roller is designed to relieve shock caused by sprocket engagement, but when the conveyed
objects are light and the conveyor length is short, an S-roller may be used.
3. An F-roller is used primarily to prevent snaking in large pitch conveyor chains. Because its flange
operates and wears against the side rail, it is not the roller of choice to convey heavy objects or
bulk material or to operate at high speeds.
 4.2.5 Chain Pitch Decision
There is only one pitch for any given small pitch conveyor chain, double pitch roller
chain, and RS attachment chain. Therefore, if you decide on the chain size according
to strength, you must also determine the chain pitch at the same time. Chain pitch is
measured in inches.

There are a couple of chain pitches for each size of large pitch RF conveyor chain.
You must first choose the right size, then select the chain pitch. Large pitch chain is
measured in millimeters.

The spacing of conveyed objects and the relationship between the sprocket diameter
and amount of available space can impact the chain-pitch decision. For example,
when pushing unit materials with a pusher at intervals of 2 m, you must select a
chain pitch that is a multiple: 50, 100, 200, 250, 500 mm.

In general, here is how larger pitch chain compares to smaller pitch chain:

1. Larger pitch chain costs less.

2. Attachments on larger pitch chain are stronger.
3. Because of the decrease in the number of teeth in the sprockets, chordal action is greater.
4. Larger pitch chain systems tend to be noisier.
5. The pin and the bushings of larger pitch chain wear faster.

6. 4.2.6 Deciding the Number of Sprocket Teeth

The number of sprocket teeth is limited by the chain pitch and the chain speed (Figure
4.18). If noise is a consideration, consult the manufacturer.
 4.2.7 Deciding the Attachment Type
See the chapters on standard, Plus α Alpha, and special attachments in
theApplications section.

4.2.8 Calculation of Tension

Here we have an example to determine the tension in a horizontal conveyor and free
flow conveyor.

Terms

 Tmax: Maximum chain tension (kN).

 T: Static chain tension at each part of conveyor (kN).
 Q: Maximum weight of conveyed objects (t/h).
 V: Conveying speed (the chain speed). (m/min.).
 H: Vertical center distance between sprockets (m).
 L: Horizontal center distance between sprockets (m).
 C: Center distance between sprockets (m).
 m: Mass of the working portion of the chain (kg/m). The mass of the chain x number of the chain
strands, bucket, apron, etc.
 M: Mass of the conveyed object in conveying section (kg/m).
 f1: Coefficient of friction between the chain and the guide rail when conveying.
 f2: Coefficient of friction between the chain and the conveyed objects in the accumulating section.

4.2.8.1 Horizontal Conveyor

4.2.8.2 Free Flow Conveyor
4.2.9 Allowable Load of Roller and Standard A
Attachment
There are two kinds of allowable roller load: one is caused by load weight (Figure
4.21); the other by corner rail (Figure 4.22).
Each manufacturer's catalog shows the allowable roller load, according to each roller
type and design. Check the appropriate catalogs.

Note: The values listed for bearing roller chain and plastic roller chain are for unlubricated
operation; the values for other types of chain are for lubricated conditions.

On the standard A attachment, bending load occurs from the carried load. Twisting
forces may also occur, depending on the direction of the load. The manufacturer's
catalog shows the allowable load for bending load.
 4.3 Selection Example
Now that we've covered the procedures you need to follow to choose a conveyor
chain, let's complete an example.

Your assignment: Select a suitable chain for the conditions shown in Figure 4.23.

1. Operating conditions (Figure 4.23). In addition, note the following:

o The conveyed object is steel pipe supported on a plate.
o The system operates in a clean environment.
o The environment and conveyed objects are at ambient temperature.
o The chain can be lubricated.
2. The chain conveyor type: loading on slat conveyor.
3. The chain type: check both RF and RF-B types.
4. The roller type: R-roller.
5. The chain pitch: 250 mm.
6. The number of sprocket teeth: based on the chain pitch and the chain speed, select six teeth.
7. The attachment type: A-2.
8. Determine the chain size from the tension.

In this example, two sets of chain convey 80,000 kg. Therefore, each of the selected
chains must be able to carry more than 40,000 kg per one set.

Table 4.5 shows you that either RF17 (general series) or RF10-B are acceptable.

Note: We are ignoring the dynamic tension of starting and stopping to make the example
easier to understand.

9. The allowable roller load.

Chain pitch is 250 mm and the length of the conveyed object is 1,000 mm.

Object length /pitch = the number of rollers under the conveyed object.

1,000 /250 = 4 rollers

If we use two sets of chain, there are eight rollers under one conveyed object. If the
steel pipes on the plate are not carried equally, uneven load occurs on the roller. In
this process, we presume that only four rollers share the load.

The roller's load = (2,000 × g) / 4 = 4,900 N = 4.9 kN

According to the catalog, either RF26 (standard series) or RF12-B (roller bearing)
may be selected.
10. The allowable load of standard A attachment.
There are eight A attachments under each pallet. Assume that four attachments receive the load
equally. The load on the A attachments = 4,900 N. According to the catalogs, RF12 (basic series)
or stronger is acceptable.
11. Taking into account the tension, the allowable roller load, and the allowable load for standard A
attachments, RF26250-R (general series) or RF12250-BR (roller bearing) may be selected.
12. Motor size.

Motor (kW) = (T × V) / 54.5 × (1 / η) (η = 0.85 motor efficiency)

When using bearing roller conveyor chain, f1 = 0.03.

T = 2,000 kg × (g / 1,000) × 40 pieces × 0.03 = 23.5 kN {2,400 kgf}

kW = (23.5 × 10) / 54.5 × (1 / 0.85) = 5.1 kW

When using RF series conveyor chain, f1 = 0.08.

T = 2,000 kg × (g / 1,000) × 40 pieces × 0.08 = 62.8 kN {6,400 kgf}

kW = (62.8 × 10) / 54.5 × (1 / 0.85) = 13.6 kW

The process is straightforward and logical. And you can see that a bearing roller
conveyor chain, because it has lower friction, allows you to use a smaller chain and a
smaller motor.