Ensuring coil packaging machine chains are properly lubricated is essential for long-lasting performance. This lubrication guide, focuses on addressing the unique demands of these chains, improving operational efficiency, and minimizing unexpected downtime.
Coil packaging machines rely on chains to perform some very important tasks in the process, good understanding on lubrication will make the operation more effective and will prolong the chain life and maintain the machine working with less down time.
Understanding Chain Lubrication Essentials
A chain is essentially a series of journal bearings linked together to transmit force and motion through sprocket engagement which is found in driving and conveyor chains. Each chain joint acts as a bearing, making proper lubrication crucial for maximizing the chain’s lifespan. The primary goal of chain lubrication is to minimize wear between the pins and bushings within the chain joints. Also it needs to flush out any debris and foreign materials that go in the process. It smooths the chain’s engagement with the sprocket. Lubrication also can inhibit rust and corrosion and dissipate heat, so that it can cushion impact forces.
Chain Types and Applications in Coil Packaging Machines
Several chain types are used in coil packaging machines, each suited to different operational demands:
- Precision Roller Chains: These are suitable for a broad range of speeds and loads commonly found in various sections of the machine.
- Engineering Steel Chains: These are ideal for slower-speed, high-load applications, such as handling heavier coils.
These chains are used in slat, apron, pusher, and crossbar conveyors within the coil packaging process.Common Modes of Chain Failure
Understanding how chains fail is crucial for implementing effective lubrication strategies:
- Tensile Failure: Occurs when the chain is overloaded, causing it to stretch or break due to exceeding their limit.
- Fatigue Failure: Results from repeated tension loading, leading to microscopic cracks in the link plates or sidebars until failure happens.
- Wear Failure: Material loss through sliding, abrasion, or corrosion. This results in malfunction or breakage. Lubrication targets wear reduction, with the goal being to increase equipment availability.
The Wear Process and Lubrication’s Role
Chain wear typically progresses through three stages:
- Rapid Initial Wear (Run-In Wear): High spots on pins and bushings wear off, it’s like the chain is setting in to find the perfect fit. Minor misalignments are corrected.
- Constant Slow Wear (Lubricated Wear): Pins seat properly in bushings, and bearing areas are well-lubricated. This is where great lubrication really shows its worth.
- Terminal Wear: Lubrication becomes ineffective, the hard case on pins and bushings wears through, or chain elongation increases loads on individual joints.
Proper lubrication can extend chain life significantly, potentially by as much as 100 times which is crucial in a busy coil packaging facility. Lubrication prevents uneven wear, reduces power consumption, prevents temperature increase, and ensures smooth operation.Choosing the Right Chain Lubricant
Selecting the right lubricant is vital. The lubricant should penetrate internal surfaces and maintain an effective film under prevailing temperatures and pressures.
| Temperature Range | Recommended Viscosity |
|---|---|
| Lower Temperatures | Lower Viscosity |
| Higher Temperatures | Higher Viscosity |
A high-quality, non-detergent petroleum base oil is generally acceptable. Additives like anti-foaming, anti-oxidizing, and extreme pressure additives can also add value. It’s always best to avoid impure oils, as acids or abrasives can damage the chain. Grease should only be used if the chain has fittings for grease injection because it may not cover all needed areas, and regular oil is best.
Lubrication Methods for Chain Drives
Recommended lubrication methods vary based on the machine and requirements:
- Manual Lubrication: Periodic oil application with a brush or spout.
- Drip Lubrication: Oil dripped between link plate edges at a controlled rate.
- Oil Bath Lubrication: A chain section runs through oil in the casing.
- Slinger Disk Lubrication: A rotating disk slings oil onto the chain.
- Oil Stream Lubrication: Oil pumped to nozzles delivers a stream or spray onto the chain.
In all methods, oil should be applied to the upper edges of the link plate or sidebar in the lower span of the chain, which helps it to evenly disburse.Lubrication best practices for Optimal Results
Here are some of the best practices that can be followed when it comes to chain lubrication:
- Proper Cleaning; Before applying a lubricant, make sure you properly clean the area where the chain wil go. This will improve adhesion and ensures better overall coverage.
- Make good use of only high quality products. These are designed specifically for the chain, and can resist higher temperatures when comparing to generic oils or greases, which are made with better material.
- Apply enough lubricant so as not to starve any part of the system. This makes sure you avoid overheating because of insufficient oiling points.
- Follow what is recommended by the manufacture about the frequency of the application and type (Grease or Oil). This will help to maximize efficiency and minimize wear on parts over time.
Lubrication of Chain Conveyors
Lubrication method is based on speed, environment, and accessibility. Continuous or periodic lubrication is crucial unless special sealed joint chains are used. Manual lubrication might be adequate for slow-speed conveyors, but moderate to high-speed conveyors need drip or oil stream lubrication, which is important at high speeds.
Maintenance and Best Practices
- Follow designated schedules and use the specified grade of oil for manual lubrication.
- Wipe chains clean with kerosene or a nonflammable solvent before re-lubricating.
- Ensure proper flow rate and direction for drip lubrication.
- Check and maintain oil levels in reservoirs for oil bath, slinger disk, and oil stream lubrication.
- Check for leaks, foaming, or overheating, and ensure orifices and nozzles are clear. Change oil after the first 50 operating hours and then after every 500 operating hours.
By following these guidelines, coil packaging machine operators can significantly extend the life of their chains, reduce downtime, and improve overall operational efficiency. When taking care of the chain operations will run smoothly.Chain Terminology
- Pitch: Distance between the centers of consecutive chain joints.
- Side Bar/Link Plates: Tension members connecting consecutive joints.
- Joint: Where the chain articulates to engage the sprocket.
- Guide: A plate or rail on which the chain rides. So this adds support to it
- Pin: The innermost member of a chain joint.
- Bushing: The intermediate member of a roller chain joint.
- Strand: Multiple rows of link plates, bushings, and rollers assembled onto a common pin.
Chain Lubrication Systems
To ensure that the performance is optimal, there are a variety of Lubrication Systems such as one for contact lubrication. It has a guiding plastic piece, which is beneficial in reducing wear.
Other advantages:
Suitable for roller chains.
Various types of chain lubricants are applicable, no matter the type of oil, there should be an option.
Can withstand both low and high chain speeds.
The machine won’t get damaged by contamination or hits to machine.
Lincoln Automated Chain Lubrication Systems
Pros;
Increases life expectancy of chain.
Minimize the time to resolve issues, because there will be less with this lubrication solution.
Reduces lubricant consumption.
Lessens noise.
Suitable chain Lubricants:
It is important to have the relubrication of the chain, with a chain lubricant.
Good at penetration
High pressure resistance.
Great corrosion protection.
Environmental factors for chain maintenance
It is very important to note the enviornment that the chain is held up with,
These extreme scenarios call for products which fall under the specialty lubricants umbrella. We have entered an area where typical mineral base oils and additives will cease to function adequately.Fully Automated lubrication systems are needed, due to lubricant dissipation and degradation. Its also just safer to run and works accurately every time, compared to manual runs.
Coil packaging machine chains need the right lubrication for long life. The correct lubrication extends chain life and minimizes downtime, optimizes lubricant use,improves safety, and creates a safer, and more productive working environment
