Measures to Solve Chain Deviation in En-masse Conveyors
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The En-masse conveyor is a core device for conveying bulk materials. Chain deviation is a common fault during operation. If not dealt with in time, it can easily lead to chain wear, scraper deformation, trough blockage, and even equipment shutdown, which seriously affects production efficiency and equipment life. The following are the summarized solutions.
Solutions
1.1 Check the installation quality and take corresponding measures to adjust and correct the installation dimensions
- Check and adjust the connection of the flange inner mouth of each section of the trough to ensure it is flat and tight. If there is any misalignment, it is only allowed to be slightly lower than the flange mouth in front of the scraper chain operation, with a value not exceeding 2 mm.
- Adjust the gap between the chain and the trough. An appropriate gap value can ensure the normal operation of the conveyor, reduce energy consumption, and extend the service life of the scraper chain and trough, thereby improving conveying efficiency. For example, if the trough width is 812 mm, the gap should be 10–20 mm.
- Adjust the En-masse conveyor bottom plate width direction level to within 2.0 mm/m.
- Check and adjust the longitudinal flatness of the upper surface of the En-masse conveyor load-bearing guide rail. The error should be less than 2.0 mm/5 m in the total length direction and less than 5 mm. The guide rail joints should be smooth, and there should be no scraping, jamming, or collision with the chain at the joints.
- Check and correct the head and tail wheels to ensure they are aligned so that the chain and sprocket can mesh correctly.
- Correct or replace deformed scrapers.
- Repair or replace worn guide rails.
- Adjust the tensioning device. The scraper chain should be neither too loose nor too tight, and the tension on both sides should be as equal as possible.
1.2 Adjust the feeding point
Material impact is an important factor affecting chain deviation in En-masse conveyors. Therefore, it is necessary to correctly adjust the feeding situation. By installing a baffle at the inlet, the material can be made to fall in the middle position of the scraper chain, ensuring even force distribution on the chain and reducing the occurrence of deviation.
1.3 Take necessary forced deviation correction measures
Since the force on the scraper is quite complex, for large troughs and long-distance conveyors, even if the installation quality meets the standard requirements, other uncertain factors may still cause chain deviation. In such cases, forced deviation correction measures are usually needed. The specific method is to weld two anti-deviation blocks on both sides of the scraper chain near the chain link, one on each side, which can effectively prevent chain deviation. The length of the block should not be too close to the bottom plate, with 3–5 mm being appropriate, and the welding should be reliable. The block should not be too large. For example, if the cross-sectional size of each side scraper is 50 mm×16 mm, the welded block size can be 60 mm×40 mm×10 mm, with a spacing of 5 mm from the guide rail on each side. One group of anti-deviation blocks should be welded every five scraper chain links, which can basically prevent chain deviation caused by uncertain factors!
Achievements
After adopting the above measures, the problem of chain deviation has been completely solved. The operating effect has been significantly improved, the failure rate has been greatly reduced, and the overhaul cycle has been significantly extended, fully meeting the on-site usage requirements.
En-masse conveyor
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