The right sprocket assembly allows conveyor systems to run smoothly without damaging equipment. If your sprockets are showing signs of wear – including chipped or broken teeth – it could be a sign that you need a more robust sprocket solution.
Industrial drag chain conveyors, such as those used in the paper and pulp, sawmill and metal recycling industries, often require a special type of sprocket engineered for heavy loads – the drum sprocket.
Drum sprockets have thick teeth, plates and hubs designed to support drag chains carrying heavy bulk materials. Common applications for drum sprockets include:
• Drag conveyers that carry logs to a debarker
• Waste conveyers that transport bark, edging and trimmings out of the plant
• Woodchip or sawdust conveyers that carry materials through pulp and paper mills
• Metal recycling conveyers that transfer large scrap metal (such as crushed cars) to shredders
An important feature of the drum sprocket is its wide surface area, which helps reduce contact pressure between the sprocket and the chain. The result? Extended chain wear life.
Customized to meet your needs
Tsubaki’s Drum Sprockets are available in multiple styles, including full face, A-plate and traction wheels, to meet a variety of application requirements.
The full-face style offers the most surface area, which makes it the standard choice for most industrial applications. Tsubaki also offers a variety of hub styles, including finished bores, bushed-style and keyless locking.
To reduce installation time and costs associated with downtime, drum sprockets can come fully assembled with a shaft, sprockets, and pillow block bearings already configured for quick and easy mounting.
Pillow Block Bearing
Tsubaki’s quality of manufacturing is what sets us apart from the competition and routed from a rich history of experience. All of Tsubaki’s drum sprockets are manufactured from top-grade, heat treated steel to withstand heavy shock loading, resist abrasion, and provide long service life. Thickness minimums of each component start at ½” and go as high as 1.5” dependent on application and overall width of the drum. Tsubaki has the ability to source a variety of plate, rolled cans and pipe thicknesses based on the customer’s needs or application. Only metal which can maintain proper welds and stresses of application torque are utilized in manufacturing and will never include inferior spot or one-sided tooth welds. To learn more about Tsubaki drum sprocket assemblies and select the right configurations for your facility, contact us today.
In cement, mining, fertilizer and industrial aggregate applications, chain bucket elevators are used to transport bulk materials vertically. Demanding environments like these often challenge system reliability and require unique, innovative chain solutions. Balancing adequate strength with features that effectively defend against corrosion and abrasion can often be a challenge but is certainly feasible and should be proactively sought to enhance the reliable and predictable nature of an elevator’s operation.
For hassle-free, efficient operation, make sure your bucket elevator chain is designed with these qualities in mind:
1. Fatigue Strength: Bucket elevators are fatigue machines that subject a chain to continuous loading and unloading cycles. High-impact, heavy-duty applications of this nature call for materials of superior strength and outstanding toughness, assembled utilizing high interference press fits. Alloy and/or premium grade carbon steels are typically utilized for the chain as they offer the highest level of stability and durability.
2. Wear Resistance: Bulk industrial aggregates like finish cement and limestone are highly abrasive. Over time, the infiltration of aggressive small particles within a chain’s bearing area can cause the chain to wear and elongate, which eventually will impact the overall efficiency and reliability of the system, driving up maintenance costs and increasing the chance of an unplanned outage. Strategically deployed heat treatment methods, surface coatings and/or seals can help protect chain bushings and pins from destructive debris.
3. Corrosion Resistance: Often times elevators must transport caustic materials such as coal, synthetic gypsum or fly ash. In cases where aggressive corrosion is likely or present, heat treatable martensitic stainless steels are typically utilized for the chain pins and/or bushings. In addition, seals and/or surface treatments such as zinc galvanization may be strategically utilized.
Tsubaki WORKHORSE Chain
Tsubaki’s WORKHORSE chain was engineered to be the industrial “workhorse” of the elevator chain segment. It was specifically designed to resist the abrasive and demanding forces of aggregate elevators. Manufactured with premium, high strength and heat-treated steels, Tsubaki’s WORKHORSE Series carries premier strength ratings and demonstrates superior wear resistance, even in harsh environments. The 5000 Series was developed to resist abrasion in single and dual strand centrifugal systems, while the 4000 Series is applicable to dual strand continuous discharge systems. The Pony Series is utilized mainly in mid-size elevator applications.
High interference press fits deliver substantial fatigue resistance and market leading stability. Premium upgrades include stainless and/or plated pins and bushings, as well as various types of joint seals to help protect against abrasive and corrosive contaminants. Tsubaki’s patented SJ3™- Sealed Joint Technology and its proprietary Titan®XL – Wear Resistant Surface Treatment are common upgrades for the WORKHORSE Series chains. Both technologies have thoroughly proven to extend chain life in the most demanding applications.
Tsubaki also offers a diverse portfolio of cast, fabricated and polymeric buckets, including standard and customized designs to fit virtually any OEM system. To ensure simple and fast installation, Tsubaki can deliver pre-assembled buckets and chain. This also helps ensure that all assembly components properly fit together before arriving onsite. Matching WORKHORSE sprockets and BS-F Series Backstops are also available to accompany WORKHORSE chain assemblies.
To learn more about Tsubaki’s WORKHORSE chain, download the brochure. If you would like to have one of our field service engineers review your application in detail, please reach out to schedule a complimentary site visit.
Keyed joints are popular solutions for connecting drive shafts to additional machine components, such as gears, pulleys, and sprockets. Although keyed joints are often seen as the industry standard, they have several limitations in high-torque applications.
Understanding these limitations can help engineers identify more effective solutions for their drive shaft connections.
How keyed joints work
In a keyed connection, the “key” is a rectangular steel piece that fits snugly into carved notches, called “keyways,” on the drive shaft and the hub of a sprocket, gear or pulley. The key effectively locks the two pieces together and allows the drive shaft to transmit power and rotation to the other machine components.
Common problems with keyed systems include fretting and corrosion caused by the metal-to-metal contact between the key and the keyway. If a key fits too loosely within the keyway, backlash – or short periods of lost motion – can occur while starting, stopping or transmitting power during normal operation. If the key fits too snugly within the keyway, it might become difficult to remove over time, complicating future repair or maintenance. Trying to correct these issues by adjusting the fit of the keyway is tedious and can be expensive.
Keyways also create an additional stress point in the power transmission assembly, which reduces shaft strength and the ability to transmit torque. This is why keyed systems are not ideal for shock or impact loads, where high torque is applied in sudden, short bursts.
Alternatives to keyed joints
Other popular drive shaft connection systems include interference fits, also known as press fits. In an interference fit, the drive shaft and hub are connected by two tight fitting parts that are held together by friction once pushed together. The connection can also be welded together for added stability. Interference fits also have limitations, however, because they prevent operators from being able to easily remove the shaft from the hub for maintenance or replacement.
A keyless POWER-LOCK® system can solve many of these engineering and maintenance challenges. Tsubaki offers a keyless POWER-LOCK device which relies on concentric surface pressure to affix gears, sprockets, and other drive components to a shaft.
Benefits of a keyless POWER-LOCK system
The keyless POWER-LOCK connection is durable and not affected by torsional load reversal or impact, which can damage keys and keyway connections. The Tsubaki POWER-LOCK can also support axial loads, where force is applied through the axis of the shaft-hub connection. Typical applications with these forces include indexing tables and bevel gears.
The POWER-LOCK is also easy to install – simply slide the device into position and tighten the bolts per the instruction manual. The components can be disassembled just as easily, with most models capable of being disassembled and reinstalled 10 times, so maintenance or replacement of worn parts is simpler and faster than it is with other connection methods.
You can also eliminate the need for time-consuming machining of keys and keyways with POWER-LOCK. No metal needs to be removed from the shaft to install the POWER-LOCK, so the strength of the shaft can be kept at its original diameter. This is especially important for hollow-shaft applications and long, heavy shaft applications.
An unexpected electrical surge or an obstruction on your production line can put unnecessary strain on motors and other drive components, resulting in equipment failure and unscheduled downtime. While shocks and jams are common, and sometimes unavoidable, having the proper overload protection device can help you save on expensive maintenance and repairs.
With the Tsubaki® Electronic Shock Relay, you can detect problems on your production line before they result in costly equipment damage. The system monitors for an increase or decrease in line amperage, and, in the event of a surge, automatically shuts down the line to prevent damage to critical equipment.
How Electronic Shock Relay Works
The Shock Relay device is easy to set up, allowing you to get equipment up and running again in no time. The system requires three set-points, or overload parameters, to be established at installation. The first set-point, the amperage limit, determines the maximum amperage that is desired for the motor. The second point, the shock time, determines how long the system can continue operation if amperage exceeds the first set-point before it trips. The last point, the start time, determines how long to allow the motor to pull amperage above the amperage limit during startup.
If an overload is detected, the Shock Relay will shut down the line by sending a shutdown signal to the motor contactor and display an alarm on the Shock Relay. This allows you to safely remove the obstruction from the production line or investigate the cause of the electrical surge. Once the issue has been corrected, you can reset the system automatically or manually at the touch of a button.
Getting Started with Tsubaki Shock Relay
Shock Relays generally work with any voltage AC motor – single or three-phase – and are commonly used in applications involving conveyors or bucket elevators, like those used in the material handling or food processing industries. Shock Relays can also be used with pumps, filters, and other equipment found in water treatment or chemical plants, as well as tapping machines and drill presses relied on by the machine tool industry.
Each Shock Relay device can protect equipment that is up to 1,000 feet away, but it is best practice to have one Shock Relay monitor per motor. Shock Relays are solid state electronics with no wear components and are designed to retain set point accuracy to ensure safe, reliable and efficient operations day after day.
In addition to its Electronic Shock Relay devices, Tsubaki also offers a line of mechanical shock guards for harsh environments where dust, humidity and high temperatures create additional challenges for electronic devices.
Whatever your application needs may be, Tsubaki has the solution you need to safeguard your power equipment and eliminate unscheduled downtime.
To learn more about Electronic Shock Relay, click here or contact us today to request specific information from our team.
Cable management is an important consideration for any space that will house technology equipment or systems—including servers, computers, monitors, and more. Control rooms and data centers for powerplants, utility companies, emergency dispatch centers, and other industries providing essential services all need effective cable management solutions to ensure efficient and uninterrupted operation.If cables are not properly organized, they can get tangled and become difficult for a technician to conduct maintenance, troubleshoot and repair. They can also take up valuable desk space and are not visually appealing. The Tsubaki® Kabelschlepp® PROTUM® Office Series offers a space-saving cable management solution for these environments. The small, light cable carriers can be easily installed at workstations and in control rooms to keep cables organized and protected.
Layout allows for proper spacing between cables
With an inner width of 50 mm and the ability to install cables along both sides of the center element, PROTUM Office allows for complete separation of data and power cables. Ensuring the proper separation is important because power cables can create an electromagnetic interference that will slow the speed of data transmission if the two cables are positioned too closely together.
Easy installation saves time
Installing PROTUM Office is quick and easy – simply press the cables into the tracks. PROTUM Office also offers a high degree of customization in terms of how it is positioned to the workstation. End connectors can be fixed underneath table tops or cable ducts, to rectangular or round table legs, or to the floor.
Sleek design blends in with office environments
Tucking away electrical cables also helps keep workspaces clear and organized. With a sleek, linkless design, PROTUM Office blends right into the office environment. Available in a variety of color combinations, including silver, black, and white, PROTUM Office can also be customized to match many desk designs.
In addition to PROTUM Office, Tsubaki KabelSchlepp offers several other customized cable carrier solutions for standard applications. Our specialists are available to support customers from the planning and design stage to the onsite installation of the complete system.
To learn more about PROTUM Office, download the brochure, or contact us today to request more information from our team.
When your equipment and machinery approach torque overload, you’ll be thankful you have a Torque Limiter to protect critical drive components.
Torque Limiters are often used in conjunction with sprockets, which guide the rotational movement of equipment and machinery, and serve as an automatic safeguard against torque overload. They are usually sold separately, but U.S. Tsubaki now offers user-friendly, cost-effective Torque Limiter Sprockets, which come pre-assembled and can be made in various sizes and tooth counts for any application.
How does the Torque Limiter Sprocket work?
The Torque Limiter Sprocket works by transmitting torque via two composite friction disks, which are compressed by disk springs against the ground face of the hardened tooth sprocket. The end-user sets the torque limit by tightening the adjusting nut on the device.
During normal operation, when no torque overload is occurring, the Torque Limiter will transmit torque from the driven shaft to the sprocket via the friction disks. As the drive shaft runs, the spring will compress the friction disks against the sprocket. This creates a frictional force that transmits the power from the drive shaft to the sprocket.
When a torque overload occurs, such as during a mechanical jam, the transmitted power will exceed the set torque point, causing slipping between the friction disks and sprocket. If slipping occurs, the frictional force will no longer be strong enough to transmit the torque from the drive shaft to the sprocket. The drive shaft will continue to run, but no torque will be applied to the sprocket. Once the torque overload is removed, the Torque Limiter will automatically reset and resume transmitting torque.
Applications and Uses for Torque Limiter Sprockets
Torque Limiter Sprockets can be used for a variety of applications where continual movement of the machine is important, including conveyors, gearboxes and motors. The slipping of the friction disks allows the machine to power through temporary jams and load increases without incurring damage. Without a torque limiting device, critical drive components are at risk of failure or breakage from torque overload.
By combining the Torque Limiter and sprocket into one product, customers now have access to a complete torque limiting solution that can be customized for specific applications and machinery.
U.S. Tsubaki offers a wide selection of mechanical protection devices and Torque Limiters for any application. To learn more about Torque Limiter Sprockets and select the right configurations for your facility, contact us today.
When selecting the proper cable carrier for your application, consider the environment in your plant. Are your dynamic cables coming into contact with foreign bodies, such as hot chips, chemicals, or other contaminants that might cause damage to the cables? If so, they might need extra protection. For example, a machine tool that cuts material such as metal or glass will create shavings, chips, and other particulates that can fall on the cable track. Once inside the cable carrier, these particles will cause wear and tear on the cables and hoses as they move. This could lead to severe cutting and damaging of the cables over time, which may result in cable failure, contribute to downtime, and ultimately, lost revenue.
Selecting the right enclosed cable carrier
Enclosed plastic and hybrid cable carriers offer an additional layer of protection, ensuring that debris cannot enter the carrier. These are ideal for applications where coarse contamination, such as chips, metal parts, glass splinters or hot metal spatter, is likely. In many cases, enclosed cable carriers are also used to hide the cables for aesthetic reasons.
The IP Enclosure Rating indicates the level of protection a cable carrier provides against outside contaminants and can help you select the right cable carrier solution for your needs.
Ensuring maximum protection with the KabelSchlepp® TKA Series
The industry’s highest-rated enclosed cable track is the KabelSchlepp TKA series, which is ideal for environments where machine cutting equipment is manufactured or used. It has an IP54 rating, which means the enclosed cable track will not allow anything down to a dust particle or liquid splash to enter the carrier. This level of protection will help ensure maximum life for your cables and hoses.
The TKA enclosed cable track can be made with a variety of material types for custom applications, including custom molded materials to protect against hot chips up to 850 °C. In addition to the high level of protection it offers, the TKA series cable track uses easy-open lids for installation and inspection – offering access to the cables at any link of the cable track – and operates quietly.
To learn more about the product features, design principles and applications of TKA Carrier, download our brochure here.
For more information on other cable carrying products, including nylon, steel, and hybrid carriers, visit our Tsubaki-KabelSchlepp cable carriers page www.kabelschlepp.com. Contact us today for assistance choosing the best KabelSchlepp cable carrier for your specific application.