What Are the Causes of Chain Breakage in En-Masse Conveyors/ Buried Scraper Conveyors?
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Chain breakage may be caused by factors such as substandard chain material and manufacturing quality, overly tight or loose chains, fatigue damage due to long-term dynamic load, excessive coal loading in the conveyor, and rusting of chain links caused by corrosive water underground.
What Are the Causes of Chain Breakage in En-Masse Conveyors/ Buried Scraper Conveyors?
En-masse conveyor is a continuous material-handling device widely used in industries like smelting, mining, and grain processing. It operates by dragging a scraper chain embedded in a closed chute to convey bulk materials (powdery, granular, or small lumpy).
Its core structure includes a closed chute (material channel), scraper chain (traction and conveying component), drive unit, tensioning device, and seals. The closed design minimizes dust leakage, suiting harsh environments with high dust or corrosive materials.
It excels at horizontal, inclined, or vertical conveying with compact footprint and stable operation. However, it requires proper maintenance—such as controlling chain tension, lubricating components, and clearing foreign objects—to avoid failures like chain breakage or floating.
Chain breakage in En-masse conveyors is a typical failure during equipment operation. The core reasons can be summarized into three main categories: inherent quality defects of the chain, abnormal operating conditions, and improper installation and maintenance. The details are as follows:
I. Chain Quality and Design Issues
Material and Manufacturing Defects: The steel used for the chain may have insufficient strength(e.g., not meeting the required alloy steel standards), contain slag inclusions or cracks from the smelting process, or have substandard heat treatment(e.g., mismatched hardness and toughness). These issues can lead to a chain with a carrying capacity lower than the actual demand, making it prone to breakage under load.
Unreasonable Selection: Failing to choose the appropriate chain specifications based on the specific gravity of the conveyed material(such as heavy materials like metal ore powder), particle size, and conveying capacity(e.g., selecting chains with too small a pitch or diameter)can result in long-term overloading and accelerated fatigue breakage.
II. Abnormal Operating Conditions and External Loads
Material Jamming and Overloading: The presence of large foreign objects such as gangue or metal blocks in the conveyed material, or material clumping that causes trough blockage, can subject the chain to far higher impact forces than its rated capacity. Continuous overloading due to excessive feed rates can also lead to fatigue failure of the chain.
Harsh Environmental Erosion: In scenarios such as smelting or chemical processing, where the material contains acidic or alkaline components or the environment is damp, the chain can corrode or rust, weakening its material strength. In high-temperature conditions, the chain's toughness decreases while its brittleness increases, making it more susceptible to breakage.
III. Installation, Commissioning, and Maintenance Negligence
Insufficient Installation Accuracy: Misalignment between the drive sprocket, idler sprocket, and trough centerline, or uneven wear of the sprocket teeth, can cause the chain to experience uneven forces during meshing, with some links bearing additional stress and breaking. Improper chain tension(too tight can cause it to break, while too loose can lead to chain skipping or jamming)also increases the risk of chain breakage.
Lubrication and Maintenance Deficiencies: Failure to regularly lubricate the chain's pins and rollers with grease or using degraded lubricant can increase friction and wear. Not replacing worn chain links or scraper plates in a timely manner can disrupt the operational balance and cause local chain overload and breakage.
Component Failures: Scraper detachment, deformation, or severe wear of the trough side plates can cause the chain to deviate from its normal running path, resulting in collisions or friction with other parts of the equipment. This additional resistance can lead to chain breakage.
En-Masse Conveyor,Buried Scraper Conveyor
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