Advantage
1. High load-bearing capacity: With a high tensile strength of 60kN, it is sufficient to meet the scraper conveying needs of heavy materials.
2. Excellent fatigue resistance: The chain plate is made of high-quality alloy steel and has undergone heat treatment, making it less prone to fracture under alternating stress.
3. Easy maintenance: Simply equip with a hammer and punch to easily disassemble and replace chain links, without the need for special tools.
4. Adapt to harsh environments: The open structure is not easily clogged with materials, and the cast sprocket can tolerate certain deviations when matched with it.
5. High cost-effectiveness: Compared to engineering plastic chains, it has a longer lifespan; Compared to forging chains, the price is lower and the overall cost-effectiveness is excellent.
6. ISO standard manufacturing: strict quality control, good interchangeability, and can be installed interchangeably with similar products at home and abroad (such as PGN, SKF).
Core material selection
l Chain plate: It is usually formed by stamping medium carbon steel or alloy steel (such as 40Mn, 45Mn). Some high-end products use boron steel, which has good hardenability and toughness, and can improve hardness while maintaining impact resistance.
l Pin shaft: Made of alloy steel (such as 20CrMnTi, 40Cr), it is the most worn part and requires high surface hardness to resist abrasive wear.
Key manufacturing processes
1. Precision punching: The holes in the chain plate are processed using high-speed precision punching machines to ensure consistent aperture and positional accuracy, and to ensure precise chain pitch.
2. Carbonization/carbonitriding: The surface of the pin shaft is carburized to form a high hardness wear-resistant layer (HRC 58-62), and the core maintains toughness and impact resistance.
3. Quenching and tempering treatment: The chain plate undergoes overall quenching and high-temperature tempering to obtain a uniform tempered martensite structure with excellent comprehensive mechanical properties.
4. Quad Staking: Exclusive process technology that compresses and deforms the two ends of the pin shaft from four directions through a special mold, forming a "mushroom head" or flower shape, significantly improving the ability to prevent detachment, offsetting working stress with prestress, and extending fatigue life.
Surface Treatment
l Shot peening treatment: Strengthen the surface of the chain plate, generate compressive stress to resist fatigue cracks, and clean the surface at the same time.
l Rust proof coating: Provide galvanizing, Dacromet or blackening treatment according to the application environment to improve corrosion resistance.
Processing and Manufacturing Precision
l Size control: Following international standards, pitch deviation is usually controlled within ± 0.2mm, and chain length accuracy must meet the requirement that the deviation within 1 meter does not exceed the specified value (such as ± 1.6mm).
l Chain pre tensioning: Pretensioning treatment is carried out before leaving the factory to eliminate initial internal stress and reduce initial elongation during use.
l Flexible customization: supports the provision of multiple accessories (accessory chain plates) to meet different installation and transportation needs.
Wear and Maintenance
1.Common Failure Modes
Axle wear: accounting for about 70%, due to material (such as sand, gravel, fertilizer) entering the gap between the axle and the chain plate hole, abrasive wear occurs, resulting in pitch elongation.
Chain plate fatigue: accounting for about 20%, long-term overload or instantaneous impact can cause cracks or even fractures at the chain plate holes.
Corrosion and rusting: accounting for about 10%, chains without rust prevention treatment will rust and get stuck in salt trucks and fertilizer environments.
2.Wear quantification standard
The golden rule for whether a chain needs to be replaced is that it must be replaced when the total elongation exceeds 3% of the original length.
For 667H (P=58.75mm), measure 16 sections (theoretical length=16 × 58.75=940mm). When the measured length reaches 968.2mm or longer, it means severe wear and there is a risk of tooth skipping or even chain breakage.
3.Suggested maintenance cycle
Period | Maintenance Item | Standard / Requirement |
Daily | Inspection: Listen for abnormal noise (clicking/clanking), check chain tension. | Chain sag should be less than 2% of the center distance. |
Weekly | Lubrication: Spray high-viscosity penetrating lubricant or used engine oil (open chains do not require expensive enclosed gear oil). | Focus on lubricating the contact points between pins and plates; remove surface mud and debris. |
Monthly | Tensioning: Adjust the tensioner or reduce the sprocket center distance. | Ensure proper sag on the slack side (typically 10-20 mm). |
Quarterly | Measurement: Measure the length of 16 or 20 chain links. | Compare with original length and track elongation rate trend. |
4.Lubricant selection recommendations
Preferred: Chain specific aerosol (containing MoS2 or graphite), with strong permeability and the ability to remove abrasive particles.
Emergency: Mix waste engine oil and diesel in a 1:1 ratio, brush and apply.
Avoid: Extreme pressure lithium grease (too viscous to penetrate the inside of the pin shaft and may adhere to sand and gravel, exacerbating wear).