JOHN KING CHAINS Limited

1. Conveyor chain style and construction

1.1 Bush chain (Rollerless chain) catalogue sections
1.2 Roller conveyor chain Catalogue sections
1.3 Drag Link Chain Catalogue sections
1.1 and 1.3 with chain sliding are simple in construction and often therefore more economic, and are
more effective in dirty and/or unlubricated environments. A greater Horsepower is required.
1.2 Chain Rolling encourages smoother operation with less surging. Lower friction allows for longer
centre distances. Not suited to dirty enviroments as ingress of materials between bush and roller and
roller and linkplate will encourage seizure. Less horse power is required so smaller motors and
reduced operational cost will be available.
2. Basic Conveyor arrangement

2.1 Chain and material sliding

2.2 Chain rolling material sliding

2.3 Chain rolling material carried

2.4 Chain sliding and material carried

2.5 Chain and material sliding on an incline

2.6 Chain rolling and material sliding on an incline

2.7 Chain rolling and material carried on an incline

2.8 Chain sliding and material carried on an incline

2.9 Chain and material elevated vertically

3. Conveyor construction
There are three principal conveyor constructions. The recommended arrangement is with the drive
at the head end and the carrying and return strands well supported (see fig. 3.1).Note the catenary
sag at the head which should be equal to at least 3% of the span over which the chain is suspended.
Other methods of supporting the return run are roller support (fig. 3.2) and Wear or guide shoes (fig.
3.3). Supported carrying and return with catenary is preferred as the catenary will ensure correct
chain and sprocket engagement and more importantly reduce chain joint wear as minimum tension
and flexing is applied.

4. Chain loading
This is the total weight of the product/material to be carried on/in the conveyor This to be defined
as M.
The additional consideration of chain weight including attachments and conveying elements,
including slats, pans, buckets cross bars and fixings. This to be defined as C.
It is essential that the load distribution is considered since the calculation factors for varying material
delivery will be different to those where a uniform load applies.
5. Chain Speed

Chain speed, normally calculated in feet or metres per minute, is a critical consideration in
determining the conveyor capacity. It is in considering this parameter that conveyor chain
pitch and conveyor chain drive and idler sprocket can be determined. fig. 5.1 illustrates the
relationship between speed, chain pitch and sprocket size. The maximum recommended
conveyor will be up to 30 metres (100 feet)/minute. Chain speed is a critical influence in
smooth conveyor chain operation and extended service life. Too high speeds can create the
condition of pulsing or surging which can seriously compromise conveyor chain
performance.
The chain speed, the distance travelled by the chain in a given unit of time, is a fundamental
factor in determining the conveyor capacity. It is from this parametr that chain pitch and the
diameter of the driven wheels is derived. fig. 5.1 illustrates this relationship.

P = chain pitch [mm]

T = number of teeth
n = revolution per minute of the wheel [rpm]

n=V*1000/(P*T)=3000/(31.75*36)=2.62rpm

5.1 Intermittent contact between chain and track guides creating variations in friction factor
and pulsing. This can be controlled by reducing chain speed.
5.2 Low Conveyor chain speed can create a similar effect. Typically speed below 3 metres (10
feet)/minute.
5.3 Excessive friction due to the condition of the chain and wear strips. This could be the
result of contaminants or general wear in mating components within the system.
5.4 The polygonal effect in considering the relationship of the chain and sprockets (see fig
5.4).This can be particularly prevalent on long pitch chains and small diameter sprockets. The
designer must take care to ensure compatibility between chain pitch and sprocket diameter
to establish smooth chordal action.
6. Chain Pitch
Chain Pitch expressed in either metric or imperial dimensions is the centre distance between
pins and is determined by chain speed, sprocket diameters, loading and load distribution and
pitching of attachments and conveying elements, including slats, pans ,buckets cross bars
and fixings.

n = rpm
T = number of teeth of the wheel
R = pitch radius of the wheel [mm]

R-r = range of variation of the polygonal effect [mm]

5.5 Uneven loading on the conveyor will also influence the condition. In some case this is
unavoidable, but must therefore be taken into account in the process of chain selection to
ensure correct parameters are established.
5.6 Slip Stick will be seen on roller conveyors running at slow speed. This is often the result
of over lubrication between roller and wear strip. The friction factor is reduced to the point
where friction is greater than bush and roller bore. The roller stops turning. The intermittent
condition of roller rotation and skid causes the chain speed to fluctuate. This condition is slip
stick. It tends to occur on lighter conveyors since heavier loads will tend to increase bearing
pressure and thus friction which will encourage roller rotation. This can often be a route to
a solution if this condition is encountered.
5.7 Very long conveyors which become difficult to tension or are subject to varying
operational conditions can also be subject to pulsing or surging. The designer needs to make
additional considerations for conveyors over 80 metres(250 feet).
7. Operating Conditions
The environment in which a chain operates has a significant influence on the designers
selection. The choice of chain construction, materials and heat treatment, tolerances and
any coating or additional surface finish is fundamental in establishing the correct selection.
John King as a producer of the widest range of conveyor chains, and without the constraints
of only one range of products, is best placed to offer the customer the right chain for the
application. Considerations are as follows.
7.1 Degree of cleanliness of the operating environment.
7.2 Abrasive nature of material conveyed.
7.3 Operating temperature.
Operating temperature table 7.3
Temperature
Adjusted work load
-40 C ~ -20 C
(Maximum allowable work load) x 0,25
-20 C ~ -10 C
(Maximum allowable work load) x 0,30

-10 C ~ 160 C
160 C ~ 200 C
200 C ~ 300 C

(Maximum allowable work load) x 1,00

(Maximum allowable work load) x 0,75
(Maximum allowable work load) x 0,50

7.4 Degree of humidity.

7.5 Presence of corrosive substances.
7.6 Operation within a 24 hour period.
7.7 Loading flucuations.
8. Lubrication
In many conveyor applications lubrication is neither possible nor desirable. Lubrication can within
some circumstances form an abrasive paste. Effective lubrication is however desirable where ever
appropriate in order to minimise power absorption, wear rate and often corrosion and noise. It
influences friction factors and therefore chain pull.
9. Chain ultimate tensile strength
This figure is expressed in the catalogue in Kilo newtons and or pounds. This is the theoretical figure
at which a chain will fail in a destructive tensile test. It is an industry standard to establish the figure
at ambient temperature. This data is fundamental as the basis for the chain selection. Chain UTS is
detailed on standard production within the catalogue. For special chains outside the scope of
standard production please contact John King Engineering.
10. Chain Pull (P)

In calculating the chain pull or force for the chain, ancilliaries and load to be conveyed we
must refer to the following factors.
10.1 Chain Loading including material defined as M, chain weight and ancililaries defined as
C. See consideration 4.
10.2 Co efficiency of friction. This is defined as the force required to overcome the resistance
to movement between two surfaces. Chain within conveyors must overcome sliding friction
defined as follows.
F1 Coefficient of friction where chain sliding or rolling on a wearstrip.
F2 Coefficient of friction where material is sliding within a trough.
Chain Friction factors F1 Chain Sliding.
Chain sliding on steel track unlubricated 0.35
Chain sliding on steel track lubricated 0.20
Chain sliding on rough track unlubricated 0.45
Chain sliding on rough track lubricated 0.25
Chain sliding on non metalic wearstrip 0.18 (typically UHMWP)

It is important to consider that at start up the coefficiency of friction is 1.5-3.0 times greater
than the dynamic friction coefficient. As a general guide, in order to minimise start up
friction the roller diameter should be a minimum of 2.5 times greater than bush diameter.
When running on rollers; chain must overcome both sliding and rolling Friction F3.
The value of the rolling coefficient in the initial calculation is assumed as F3 = 0.2, whilst in
the control calculation is given as

where d=bush O/D (mm), D=Roller O/D (mm), b=coefficient dependant on material
employed and quality of contact surfaces. This is equal to 1 for stell roller on a steel track
with smooth surface and 2 for a steel roller on steel track with rough surface. The sliding
friction coefficient defined as C between bush and roller is as table 10.2.
Table 10.2
Bodies in contact
Dry surface C Lubricated surface C
Steel roller on steel busz
0.25
0.15
Roller with bronze bush on steel bush N/A
0.13
Nylon roller on steel bush
0.15
0.10
Chain Friction Factors F1 chain rolling.

where da=axle diameter (usually chain bush O.D and Dr=Roller outside diameter)
10.3 Service factor SF
Chain pull must include a multiplier to take into account the variable operating conditions of
the conveyor. This is known as the service factor. Variations in operating conditions and the
service factor (SF) as defined in the following table 10.3.
To obtain the SF each operational condition must be multiplied together.
Table 10.3 Operating conditions
Load position
- Central
- Not Central
Load characteristics
- Uniform: extent of overloading less than 5%

FS
1
1.2
1

- With minor variations: extent of overloading 5 to 20%

- With major variations: extent of overloading 20 to 40%
Frequency of loaded starting/stopping
- Less than 5 per day
- From 5 per day to 2 per hour
- More than 2 per hour
Working environment
- Relatively clean
- Quite dusty or dirty
- Humid, very dirty or corrosive
Number of hours in use daily
- Up to 10
- More than 10

1.2
1.5
1
1.2
1.5
1
1.2
1.5
1
1.2

FS=F4*F5*F6*F7*F8=1.2*1.2*1*1.5*1.2=2.592
To obtain the total S coefficient, (FS) value for each operational condition must be multiplied
together.
Gearing Factor FA
This is an adjustment coefficient made to the chain pull, which increases due to the
additional friction caused by the rotation of the chain on the drive and driven wheels.
FA = 1.05 for wheels mounted on brass bushes
= 1.03 for wheels mounted on bearings
The sum of all products obtained by the multiplying FA for the chain pull in each gearing
point determines the new total chain pull.
For the following examples the FA values will not be considered.
11. Chain Pull Calculations

Refer to section 2 Basic conveyor arrangement.

(2.1) Chain and material sliding

Where M can be calculated as M = H.B.L.b.y.1000 [Kg] or M = L.Q/3.6V [Kg]

If Q is unknown it can be calculated as Q = H.B.b.y.V.3600 [T/Hr]
(2.2) Chain Rolling and Material sliding

Where M can be calculated as M = H.B.L.b.y.1000 [Kg] or M = L.Q/3.6V [Kg]

If Q is unknown it can be calculated as Q = H.B.b.y.V.3600 [T/Hr]
(2.3) Chain Rolling and Material Carried

(2.4) Chain Sliding and Material Carried

(2.5) Chain and Material Sliding on an incline

(2.6) Chain Rolling and Material sliding on an incline

(2.7) Chain Rolling and Material Carried on an incline

(2.8) Chain Sliding and Material Carried on an incline

(2.9) Chain and Material Elevated Vertically

Note for (2.1) & (2.5) Chain and material sliding in scraper and drag link conveyors to
calculate chain pull additional parameters must be included.

F2 = Coefficiency of Friction between material to be moved and sides of trough.

L = portion of loaded conveyor.
M = Mass of product to be carried.
H = Height of sides of trough.
B = Width between sides of trough.
b = Product depth not normally to exceed 60% of trough sides.
y = specific weight of material conveyed.
V = Chain Speed (M/sec).

Table 11.1
Material conveyed
Spec. weight [T/m3] Friction coefficient F3
Oats
0.45
0.70
Wheat
0.75
0.40
Corn
0.80
0.40
Dried barley
0.45
0.70
Rye
0.65
0.40
Rice
0.75
0.40
Linseed
0.70
0.40
Dried malt
0.40
0.40
Wheat flour
0.70
0.40
Corn flour
0.65
0.40
Refined powdered sugar 0.80
0.50
Cement
1.00
0.90
Anthracite coal in pieces 0.70 to 0.90
0.40
Coking coal
0.50
0.70
Dried clay
1.60
0.70
Ashes
0.60
0.60
Cement Clinker
1.30
0.80
12. Determining chain series to utilise
Once the MAXIMUM CHAIN PULL has been established, the maximum stress that chain components
will be subjected to must be considered. It is generally considered that a chain working at 65% of its
theoretical ultimate strength will be taken beyond its elastic limit on the tension members of the
chain. In order to protect the running gear during operation it is necessary to introduce a FACTOR
OF SAFETY. The factor of safety is variable but is normally within a range where the ultimate strength
or chain breaking load should be between 6 and 10 times the maximum working load. This is
dependent on operational environment and service factor and conservative safety factors should be
employed where variations in chain pull are difficult to establish. The figure is generally established
based on experience and for this reason where uncertainty exists the technical office should be
consulted.
13. Calculation of bearing pressures

Where:
K = Load (Kgf) supported by each roller
P = Chain Pull
L = Distance through bore of Roller
LDb = Total bush length
Dr = Roller bore Diameter (mm)
Dp = Pin outside Diameter (mm)
Maximum Allowable pressures are shown in table 13.1 and 13.2
Maximum allowable pressures table 13.1
Materials in contact
Bush

Max. spec. Press.

Pin

Kgf/mm2
Case-hardened steel Case-hardened steel
2.50
Case-hardened steel Hardened-tempered steel 2.10
Cast iron
Case-hardened steel
1.75
Stainless steel
Stainless steel
1.20
Bronze
Case-hardened steel
1.00
Maximum allowable pressures table 13.2
Materials in contact
Bush

Max. spec. Press.

Pin

Kgf/mm2
Case-hardened steel
Case-hardened steel 1.00
Hardened-tempered steel Case-hardened steel 1.00
Cast iron
Case-hardened steel 0.70
Bronze
Case-hardened steel 0.60
Polyethylene A.D.
Case-hardened steel 0.10
Stainless steel
Stainless steel
0.40
Cast iron
Bronze
0.28
14. Calculaiton of power required

Once the MAXIMUM CHAIN PULL has been established, the following calculation for head
shaft power requirements should be employed.

Where:
Mt = Torque (Kg m)
N = Power CV.Hp or KW)
R = Head Shaft RPM
P = total chain pull
dp = PCD of Drive sprockets (m)
From these two relationships it is concluded

From which is derived

The useable power output to be established must take into account losses from reduction
with chain and belt transmissions.
15. Recommended sprocket sizes

Table 15.1
Conveyors
Slat, bar, steel apron, wire mesh and similar conveyors
Soft fruit and similar conveyors
Cask, package and similar elevators
Swing Tray Elevators
Ore feeders conveyors
Scraper conveyors

Normal Range of Sprocket teeth

8-12
8-12
8-12
16-24
6.8
8-12

Bucket Elevators (spaced Bucket)

High Speed Vertical Twin or single chains
Medium speed Inclined twin or single conveyors
Slow speed positive discharge elevators

Head
14-28
14-28
12-24

Bucket Elevators (Continuous Bucket)

Boot
10-20
10-20
8-16

Deflector
9-11

Medium speed vertical or inclined Twin or single chains 8-16

Slow speed vertical or inclined Twin or single chains
6-14

8-16
6-14

16. Recommendation operating speeds

Table 16.1
Conveyors
Slat, bar, steel apron, wire mesh and similar conveyors
Soft fruit and similar conveyors
Cask, package and similar elevators
Swing Tray Elevators
Ore feeders conveyors
Scraper conveyors
Bucket Elevators (spaced Bucket)
High Speed Vertical Twin or single chains
Medium speed Inclined twin or single conveyors
Slow speed vertical elevators double strand

Speed (metres per second)

0.1-0.3
0.05-0.25
0.1-0.3
0.025-0.1
0.2-0.9

1.00-1.8
0.6-1.0
0.6-0.8

Bucket Elevators (Continuous Bucket)

Medium speed vertical or inclined Twin or single chains 0.4-0.6
Slow speed vertical or inclined Twin or single chains
0.2-0.3