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Environmental chains optimise energy

Edited by the Engineeringtalk editorial team Sep 18, 2001

Bob Young of Tsubaki UK outlines the features and user benefits of environmental chains, including energy efficiency, low noise, and anti-bacterial action

The energy savings accrued from investing in inverter drives and high efficiency motors are an effective means of offsetting the effects of the government's Climate Change Levy.

In most power transmission systems, however, there are other power train components which, if not optimised for energy use, can impair the potential for achieving savings.

One product area in particular which has been overlooked by industrial consumers in this respect is chain.

Despite this lack of awareness, the potential for achieving savings is indeed real, and is proven by two innovative products, the Bearing Roller Conveyor Chain and the Double Plus chain, both of which have been developed by Tsubaki for the world market.

Unique Bearing Roller Conveyor Chain (BRCC) integrates cylindrical roller bearings inside its chain rollers, reducing the frictional coefficient of the chain to 0.03, about one third that of conventionally constructed conveyor chain.

This allows a decrease in driving power of 80%, enabling users to downsize and reduce costs by using smaller drive motors and gearboxes, and a chain size up to two sizes smaller than with conventional roller chain.

The low friction operation of BRCC is further enhanced by packing and sealing grease into the bearing area of the chain rollers.

This reduces lubrication maintenance by up to ten times, depending upon the application, and increases the superior energy efficiency characteristics of the chain.

The term 'free flow' could have been termed to describe the energy saving characteristics of Tsubaki's Double Plus conveyor chain.

Double Plus conveys at more than twice the speed of ordinary free flow chain.

Its design incorporates a large centre roller, and a smaller outer roller which supports the chain on a guide rail.

When engaged, the large centre rollers (upon which conveyed objects travel) rotate at the same rpm as the small rollers.

However, since the diameter of the large rollers is approximately 2.5 times that of the smaller ones, conveyed objects move along approximately 2.5 times faster than the chain! The benefits of this unique design are that chain speeds up to 60% slower can be used without affecting the object conveying speed.

Consequently, motor drive speeds can be reduced leading to substantial energy savings, and to reduced noise levels some 15dB lower than those of plastic side roller chains.

Energy saving is all about the environment.

At present it is probably the main concern in this respect.

However, there are others which affect the industrial operating environment, notably noise and contamination.

In addition to its initiatives with energy saving chains, Tsubaki has been alone in the chain market by producing chains which address both of these issues.

Cutting down noise in the workplace helps to reduce operator fatigue and is an indirect contributor to improved productivity.

The problem is that initiatives to reduce noise, by even a fraction, are usually quite costly.

However, one way in which companies can reduce workplace noise at relatively low cost is with Tsubaki's New Low Noise Drive Chain.

This directly replaces standard roller chain, but is between 6 - 8dB quieter in operation.

Low Noise Drive Chain reduces the noise that occurs when the chain roller and the teeth of the sprocket mesh together.

With the new design, the normal cylindrical roller is replaced by a coil spring roller.

This absorbs the noise produced when it engages with the sprocket teeth.

In addition to lower overall noise levels with this arrangement, noise is also softened and jarring noises are reduced.

In addition to noise, Tsubaki is also helping the fight against bacteria, which is a major problem in the food industry, with its new plastic Antibacterial /Anti-mould MWS series chain.

In addition to its preventive qualities against bacteria such as colon bacillus (e-Coli), staphylococcus and lactobacillus, the MWS chain has an anti-mould capability that is effective against green and other forms of mould.

The MWS Series of plastic chains is a low wear, friction resistant range that includes top chains, plastic belt chains and plastic block chains.

These are complemented by sprockets, idler wheels, return rollers and running rails that are also manufactured with anti-bacteriological properties.

This complete package simplifies the task of installation for the OEM and user.