There are many reasons why these chains and chain drives suddenly fail, including contamination, fatigue, or wear and tear. However, chain failures are almost always a direct result of lubrication issues.
So, the best way to prevent chain failure is to create and enforce a maintenance program that outlines how often lubrication is needed for your chains.
Below, we’ll discuss some of the most common lubrication methods and best practices for each method.
Manual
Manual lubrication involves using hand-held tools like grease guns, filler pumps, grease pumps, brushes, small oil cans, or aerosol sprays to lubricate specific points. This method should be done every eight to ten hours, depending on the machine or equipment’s operating procedures, and equipment must be offline/powered off. This method is known for being very time-consuming and sometimes even dangerous, based on the type of machinery or equipment being maintained.
Common Uses
In the industrial world, manual lubrication is typically reserved for smaller productions where there wouldn’t be much impact from turning off machinery or equipment.
Best Practices
- Always lubricate the links, rollers, link plates, and the sprocket’s teeth.
- Use oil because it has better flowability than grease.
- Create a lubrication map highlighting different lubrication points and the amount needed for each point.
- Ensure equipment is off; schedule maintenance during production off-hours.
Drip
Another way to keep your chains constantly lubricated is by implementing a semi-automatic drip lubrication system. This chain lubrication system manages the number of drops per minute and hour and ensures that the lubricant covers the entire chain width, rollers, and inner and outer link plates. Most drip lubrication systems drop anywhere from five to 20 drops a minute. The drip system manages the frequency and uniformity of the drops, and the number of links in the chain defines the number of drops.
Common Uses
Drip lubrication is often used in conveyor systems in multiple industries, such as automotive, mining, and food and beverage, where chains need to operate continuously.
Best Practices
- Ensure the viscosity of the lubricant you’re using is ideal based on the chain’s speed and the operating temperature. If the lubricant is too thick, you’ll encounter flow issues.
- Evaluate your drip rate to see if it’s providing the right amount of lubrication. If your system is over-lubricating, it can attract dust and debris. As a general rule of thumb, faster chains need more frequent drips, while slower chains will need a lower drip rate.
- Always check the drip system for clogs or leaks, as those are common issues with those systems.
- Place the drip outlet above the chain link pins because these areas are high-friction and need the most consistent lubrication.
Automatic
Lastly, automatic chain lubrication systems operate continuously. When working correctly, daily inspection of the chain or sprocket during operation is typically not necessary. Automatic systems help reduce maintenance and service costs while increasing machine utilization. The most common lubrication chain systems are force-feed and oil-ring.
Force-Feed
Force-feed lubrication systems provide a timed and continuous spray through a distribution pipe where the oil covers a specific surface area of the chain.
Common Uses
This system is typically used when the driven chain must handle high operating speeds and loads or high temperatures, such as in excavators, bulldozers, robotic systems, turbines, and generators, or in a highly contaminated environment.
Best Practices
- Use adjustable metering valves to adjust delivery to each lubrication point.
- Check the reservoir frequently to ensure it’s filled with lubricant. If air enters the system, it could damage the lubrication pump.
- Regularly inspect distribution lines, hoses, and fittings for leaks and blockages.
- Track lubricant usage to determine where settings need to be adjusted.
- Install an automated level sensor that can alert your operators when lubricant levels are low.
Oil-Ring
Oil-ring systems use rotating discs that gather the oil from a reservoir at the bottom of the drive chain system. The oil is then sprayed or jettisoned against a collector plate, which is then dropped on the bottom of the chain. With these systems, the amount of lubricant is managed to ensure the chain is never entirely immersed in the lubricant. The primary difference between oil-ring and force-feed systems is that oil-ring systems don’t need pumps or external power—they rely on gravity and the rotational motion of the ring to provide lubrication.
Common Uses
Oil-ring systems are commonly used in moderate-speed, continuous-duty applications. They are preferred over force-feed systems when there are budget constraints or when there are a large number of units or equipment that need to be maintained, like HVAC systems.
Best Practices
- Always keep the oil levels in the reservoir within the recommended range to prevent over-lubrication and under-lubrication.
- Check the ring periodically for damage or misalignments.
- Clean out the reservoir each month to remove contaminants.
- Inspect the seals for leaks.
- Never operate over the recommended temperature range, which will degrade the oil.
Get More Advice From DropsA Today
Founded in 1946, DropsA has long been recognized as an innovator, manufacturer, and trusted provider of affordable and efficient chain lubrication systems and parts. Visit our online shop to browse our products and solutions, or contact us today for more advice about chain lubrication or help with selecting a product.