Project: Chain Drives

Overview
You are probably familiar with the chain drive systems on bicycles. Pedals are attached to the sprocket, and
the pedal power is transmitted to the small sprocket on the rear hub to propel the bike. Industrial chain drives
are more complex, but the operating principle is the same.

A chain drive system has an endless chain with links that mesh with sprocket teeth to transmit power.
Because chain drives maintain a constant relationship between the driving and driven shafts, they can
transmit power without slipping. The roller chain is the most versatile and widely used of all chain designs.
Skill Outcomes
Upon completion of this activity, you will be able to:
• Break chain
• Install, align, and tension chain drives
• Perform Preventive Maintenance
• Troubleshoot Chain drives
Roller Chains
A roller chain consists of alternating roller links and pin links. The pins in the pin link rotate freely within
bushings on the roller link. The rollers are evenly spaced around the entire length of chain to keep the chain
flexible enough to contact the sprocket teeth. Roller chains can have different configurations, depending on
how they are used. The next figure is a typical roller chain link.

Roller link: two pin link plates, two bushings, and two rollers
Pin link: two link plates, one with pins that connect two roller links
Chain Pitch: distance from center of one pin to the center of the next pin on the chain
Chain Width: distance between the link plates of a roller link
Roller Diameter: outside diameter of the roller

Most chains have an even number of links, with the same number of roller links and pin links in the chain.
This leaves each end of the chain with the end of a roller link. Master links, or connecting links, hold
together even numbers of links. Offset links, like the one below, hold together an odd number of links, as
they have one roller and one pin.

MECE 3102 Tribology Dr. Tsapi Kevin

DEPARTMENT OF MECHANICAL AND INDUSTRIAL ENGINEERING (MIE)
NAHPI Reference IMP-1 – Mechanical Power Transmission Page 1
Master Links

Master links, also called connecting links, are used to join two disconnected ends of a chain into a
continuous loop. Master links consist of pin link, a chain plate, and spring clip. To install a master link, the
pin link is passed through the roller links at the ends of the chain, and the chain plate is put over the other
side. Then the spring clip is clipped over the grooves in the pins to hold the entire assembly together. When
installing a master link, make sure the master link and spring clip are easily accessible for chain maintenance
and replacement. Also keep in mind the direction the chain will be running, so that the clip may be attached
in the direction least likely to come off during operation. This means that the open end of the clip should be
facing away from the direction of motion of the chain.

Roller Chain Operation

During each complete cycle, every link of a roller chain undergoes cyclic loading. This means that in the
chain’s working strand, the chain is under full tension (load) and the slack strand is under minimum tension.
See the figure below.

Chain Sprockets

Chain sprockets are wheels with specifically spaced teeth for use with matching roller chains. The pitch of
the chain and tooth pitch of the sprocket must match for proper operation of chain drives. Ratios can be
created with chain and sprocket to either increase or decrease the speed from a driver to a driven shaft.

Breaking a Chain

MECE 3102 Tribology Dr. Tsapi Kevin

DEPARTMENT OF MECHANICAL AND INDUSTRIAL ENGINEERING (MIE)
NAHPI Reference IMP-1 – Mechanical Power Transmission Page 2
Maintenance Technicians must frequently prepare a length of chain from a longer length of replacement
chain. Standard replacement roller chains are 10 to 100 feet long. To remove a section suitable for a specific
application, you must remove a pin from one of the links. You can then separate the links that were held
together by that pin. This is called breaking the chain.

Chain Drive Preventive Maintenance

If a chain or sprocket fails, the manufacturing process may shut down. To avoid breakdowns, you must
perform periodic maintenance and inspection on chain drives. Regular preventive maintenance can prolong
the life of a chain drive.

Chain Lubrication

A clean supply of film lubricant (oil) is required as:

• A film to avoid metal-to-metal contact between chain links and sprockets.

• Coolant.
• A shock protector for the chain.
• Protection from contaminants such as dirt and moisture.

Use a good quality, non-detergent oil that will flow freely into chain joints. Do not use grease or extremely
heavy oil, which have poor flow characteristics. As a rule, use:

• SAE 30 oil for most applications.

• a lighter oil (e.g. SAE 20) in extremely low operating temperatures such as 20 °F.
• SAE 40 or 50 at high operating temperatures above 100 °F.

Lubrication Techniques

The next figure shows three lubrication techniques for roller chains.

TYPE A – Manual or Drip Lubrication

• Use the drip method to adjust the oil flow according to chain speed.
• Apply oil with a spout can or a brush applicator, or by drip method.
• Perform can and brush methods at specified intervals of machine operation.

TYPE B – Bath or Disc Lubrication

• In the oil disc method, a disc picks up oil from a reservoir and delivers it to the chain.
• Route the chain through an oil bath on the low side of the system, where links pick up oil.
• Check the oil level at required intervals and refill as necessary.

TYPE C – Oil Stream Lubrication

• A circulating pump supplies oil in a constant stream.

• Carefully adjust the nozzle position and flow rate to distribute the right amount of oil evenly over the
chain.

MECE 3102 Tribology Dr. Tsapi Kevin

DEPARTMENT OF MECHANICAL AND INDUSTRIAL ENGINEERING (MIE)
NAHPI Reference IMP-1 – Mechanical Power Transmission Page 3
The following chart outlines the periodic Preventive Maintenance (PM) procedures you will perform on
chain drive systems.

Troubleshooting Chain Drives

Troubleshooting skills depend on applying common sense when you are analyzing a problem. By adding
competent testing techniques and basic operational concepts, you can effectively troubleshoot chain drive
systems.

Gathering information is the first step in troubleshooting. Obtain the information by observing machine
operation and components, listening for any unusual noises during operation, identifying odors, and feeling.

MECE 3102 Tribology Dr. Tsapi Kevin

DEPARTMENT OF MECHANICAL AND INDUSTRIAL ENGINEERING (MIE)
NAHPI Reference IMP-1 – Mechanical Power Transmission Page 4
This chart lists indications of problems, their causes, and the corrective actions required when you are
troubleshooting chain drive problems.

Review

Answer the following questions:

Question 1 List three reasons why it is important to maintain a clean supply of oil on the chain.

Question 2 List the three methods of lubrication used on roller chains.

Question 3 Why should grease and extremely heavy oil not be used to lubricate chain drives?

Question 4 What may happen to the sprockets if a drive chain is too loose

MECE 3102 Tribology Dr. Tsapi Kevin

DEPARTMENT OF MECHANICAL AND INDUSTRIAL ENGINEERING (MIE)
NAHPI Reference IMP-1 – Mechanical Power Transmission Page 5