CHAIN CONVEYORS

By R.Jayaraman
 INTRODUCTION

Chain as a pulling member is extensively
used for transporting the materials
from one position to another, both unit
loads and bulk materials .

Unit loads are moved by providing a flat
surface attached to the chain. These flat
carrying members are referred to as
slats.

Depending upon the quantity to be
moved one or two chains are used.

Endless chain or twin chains pass around
the sprockets at the head and foot ends.

2
 TYPES OF CHAIN CONVEYORS

Chain conveyors are classified as
follows:
1. Apron Conveyors/Feeders
2. Flight Conveyors
3. Drag Chain Conveyors
4. En masse Conveyors
5. Slat Conveyors

When the material is carried in
overlapping pans attached to the
chain, it is called an ‘Apron
Conveyor'.

An apron conveyor when used
for controlling the rate of feed, as
from an overhead hopper, is also
3
called Apron Feeder.
 TYPES OF CHAIN CONVEYORS

When materials are moved by cross
members attached to chain, it is called
flight conveyor. It is so called because the
cross members are referred as flights.

These conveyors are also called ‘Drag
Chain Conveyor’ as the material is
dragged from the bottom surface of the
trough and discharged at specified
locations from the bottom trough.

For moving unit loads such as bags,
containers, drums, packages etc a flat
surface in the form of slats are attached to
the chain/Chains

4
 APPLICATIONS
1. For bulk materials the choices are apron
conveyors and flight conveyors.
2. Apron conveyors are generally used for heavy
duty applications whereas flight conveyors can be
used only for small lumps and powdery
materials.
3. Because of their heavier construction, apron and
pan conveyors are capable of handling heavy,
lumpy and abrasive materials which would
damage lighter types of conveyors within a short
time.
4. They are frequently used as supply feeders for
large crushers, breakers and pulverizers
5. For unit load applications slat conveyor is the
main choice, though apron conveyors are also
used e.g. sugarcane etc.
6. Slat conveyors will carry all kinds of parts and
packages, light, heavy and bulky.
7. Like apron conveyors, they can operate on
horizontal, inclined or a combination of both.
5
 APPLICATIONS
1. Typical applications are: barrels, boxes, crates in
refineries, machined and assembled parts in
automobile industry, coils of wire in wire mills,
flasks, castings in foundries, bales, packages, sacks
in processing plants,
2. Flight conveyors push the material along the
trough or tube by means of cross members called
flights which are attached to the chain.
3. As these flights move along with the chain ,
material is pushed along the trough till it
discharges through an opening in the trough.
4. The main advantage of the flight conveyors is that
it can be loaded and unloaded at intermediate
points.
5. Flight conveyors are used for conveying and
cooling of ash or slag.
6. Flight conveyors are not suitable for brittle,
moist and sticky materials
6
 CHAIN TYPES
According to conveyed object type (unit or bulk
materials), typical chain conveyor types are sorted as
shown below.
The available chain types are abbreviated below.
These abbreviations mean:

RF: Double pitch roller chain,

RF conveyor chain. Plastic roller and plastic
sleeve chain may be used to convey unit materials.

RS: RS attachment chain

RF-B: RF bearing roller conveyor chain

RFN: Bearing bush chain

RFD: Deep link chain

VR: DOUBLE PLUS® chain

7
 INTRODUCTION
Trolley Conveyor RF
Trolley Elevator RF-B, RFN, RF (CT)

Bucket Elevator RF, Special Chain

Bucket-Type
Continuous Unloader

Scraper/Flight Conveyor RF

Flow Conveyor RF, NFX

8
 COMPONENTS OF CAIN CONVEYOR
Basic Structure of Single Pitch Conveyor Chain with K1 Attachment

Basic Structure of Double Pitch Conveyor Chain with A2 Attachment

Large pitch conveyor chain has the same basic structure as double pitch conveyor chain but there are
some differences.
Large pitch conveyor chain has a headed pin, sometimes a flanged roller (F-roller), and usually does
not use a riveted pin.
Large pitch conveyor chain is also called engineering class chain.
9
 ENGINEERING CLASS CHAIN

10
 FUNCTIONS OF CHAIN PARTS
Plate
The plate is the component that bears the tension placed on the chain. Usually this is a repeated loading,
sometimes accompanied by shock. Therefore, the plate must have not only great static tensile strength, but also
must hold up to the dynamic forces of load and shock.
Pin
The pin is subject to shearing and bending forces transmitted by the plate. At the same time, it forms a load-
bearing part, together with the bushing, when the chain flexes during sprocket engagement. Therefore, the pin
needs high tensile and shear strength, resistance to bending, and also must have sufficient endurance against shock
and wear.
Bushing
The bushing is subject to shearing and bending stresses transmitted by the plate and roller, and also gets shock
loads when the chain engages the sprocket.
Roller
The roller is subject to impact load as it strikes the sprocket teeth during the chain engagement with the
sprocket. After engagement, the roller changes its point of contact and balance. It is held between the sprocket
teeth and bushing, and moves on the tooth face while receiving a compression load.
Cotter Pin, Spring Clip, T-Pin
These are the parts that prevent the outer plate from falling off the pin at the point of connection. They may wear
out during high-speed operation, therefore, for this application, these parts require heat treatment.

11
 FUNCTIONS OF CHAIN PARTS
Sprockets

The chain converts rotational power to pulling power, or pulling power to rotational
power, by engaging with the sprocket.

The sprocket looks like a gear but differs in three important ways:

Sprockets have many engaging teeth; gears usually have only one or two.

The teeth of a gear touch and slip against each other; there is basically no slippage in a
sprocket.

The shape of the teeth are different in gears and sprockets.

12
 CHAIN ATTACHMENTS
Standard Attachments
There are many different types of attachments; it would be difficult for chain manufacturers to satisfy all
customer requirements.
Current standard attachments are established and selected based upon the long history of attachment chain
use and demand, and they provide high quality, economy, and quick delivery to meet the majority of
customers requirements.
For small pitch conveyor chains, standard attachments include: A, K, SA, SK, D-1, and D-3 types
A Attachment

An A attachment is most commonly used.

It has a bent link plate that extends out on one side of the chain, forming an L-shape.

It comes with one or two bolt holes, which are referenced A-1 or A-2, respectively.

The attachment interval can vary (for example, on each chain link, every five links, or two attachments in a
series with intervals every four links, etc.).

Generally two strands of chains with slats are used .

A2 Attachment
A2 Attachment with Slat
13
 CHAIN ATTACHMENTS
K Attachment
This is an attachment made by installing A attachments on both sides of the chain.
The attachment is called K-1 or K-2 based on the number of bolt holes on one side.
The attachment interval can vary the same as the A attachment

K1 Attachment
The top of the attachment is higher than the R-rollers, so slats can be installed over the chains.
Objects can also be conveyed directly on the K attachments.
The return side of the K attachment chain cannot be supported with guide rails on the rollers. The
return may be slack or supported in some other way.

14
 CHAIN ATTACHMENTS
When a wide slat is installed on two A attachment chains, the slats may not be able to
support the weight. A chain with K attachments is installed between the A attachment
chains to help support the load.

15
 CHAIN ATTACHMENTS
SA Attachment
For the SA attachment, the link plate is extended on one side of the chain, and one or two
bolt holes are installed.
These are called SA-1 or SA-2 depending on the number of the bolt holes .
The attachment interval can vary the same as the A attachment. These attachments may be
adapted for use with hooks or slats
The SA attachment is simpler and stronger than the A attachment, and may receive bending
and twisting force depending on the direction of the loads.
The return side of the chains can be supported by guide rails on the rollers unless bolts
extend into the attachment.

16
SA2 Attachment
 CHAIN ATTACHMENTS
D Attachment (Extended Pin)
In this form, the one end of the pin is extended. The attachment interval can vary the same
as the A attachment.
Two sets of D attachment chains can be connected to cross rods, or jigs (such as blocks)
may be installed.
The extended pins are subjected to bending and shearing forces.
The allowable load of D attachment that is shown in a manufacturer's catalogue is based on
a bending force concentrated at the centre of the extended pin.
The return side of the D attachment chain can be supported by guide rails on the rollers

D3 Attachment D Attachment with Cross rods and Jigs

17
 SLAT CONVEYORS

Slat conveyors are built with carrying members of wood or metal slats attached to a single or
double strand chain.

In addition to conveying operations they may be used as a traveling worktable, or a
combination of the two.

Many kinds of parts and packages can be carried light, heavy or bulky units on inclines as well
as on the horizontal.

Slats can be designed and shaped to suit the articles to be handled

18
 APRON CONVEYORS

Apron Conveyor consists of overlapping or hinged steel pans supported between or mounted upon two
strands of roller chain riding on single flanged rollers to form a continuous moving bed for bulk materials.

When these aprons are provided with vertical plates on sides, it is called a pan conveyor.

The speed is usually less than 30 m/min. They are not suitable as long conveyors.

When used below the hoppers for withdrawing of material , they are called Apron Feeder. Apron feeders
operate at 3 to 10 m/min.

The inclination limit is 25 deg, because with a steeper slope material will slide back unless the apron is
provided with cleats.

An apron feeder to control the rate of flow from an overhead hopper if inclined will reduce the depth of the
hopper pit substantially.

Apron feeders have fixed side plates or skirt boards which protect the chain and permit the load to be carried
at considerable depth without spilling over the edge of the apron. A thick bed at slow speed is preferred to thin
bed at high speed.

When apron feeder is used for heavy duty application, to withstand shock at the loading point, the pans are
made of manganese steel or high carbon steel with impact T rails about 5 mm below the bottom of the apron
so that as the pans yield under impact they bring up against the rails before permanent deflection occurs.
19
 APRON FEEDERS

Apron Feeders are provided for extraction of material from
hoppers and bins and for applications having high impact
loads. These feeders are used for controlled volumetric
feeding of bulk materials.

The apron feeders have reinforced double beaded overlapping
pan design and heavy-duty frame construction to absorb high
impact loads and to conduct positive extraction from
hoppers/silos.

The apron feeders are tailor made for handling any type of
application from feeding run-of-mine quarry rock with
lumps as large as 2000 mm dumped on to the feeder to light
duty applications for extracting crushed material from small
bins.

Apron feeders are made in three different basic designs such
as
a) Heavy Duty Frame roller supported feeders,
b) Outboard roller supported feeders and

Light Duty Chain roller supported feeders.

They are made in widths varying from 300 to 2400 mm and
can handle capacities as high as 9000 TPH.

The capacity at a given speed is a function of the depth of the
load, its weight and the width between the skirts. An
allowance is made for slip due to drag against the skirts. In a
horizontal conveyor 75% is taken as the loading for
calculating the capacity
20
FLIGHT CONVEYORS

The fight conveyor has an endless chain or twin chains passing
round the sprockets at the head and foot ends with spaced
transverse scrapers called ‘flights’ which push the material
along the trough.

Flight conveyors can be of considerable length but as the
material is scraped along the trough, they are not suitable for
abrasive materials like sand and ashes. However, a modified type
called drag-chain conveyor is specifically adopted for the ashes.

Flight conveyors can operate at slope of 40 to 45 deg at greatly
reduced capacity. If the slope is greater than 25 deg, the flight
depth must be sufficient to prevent backward cascading of the
material.

The flights are steel plate or malleable iron with thickened
edges. In the double strand conveyor with wide flights they are
reinforced by angles for stiffness.

For moderate duty , low capacities and small lumps, the single
strand scraper flight conveyor is best suitable.

These are used in coal outlets to distribute the coal to many
bins.

Those with shoe suspended flights are similar, except that the
flight does not touch the trough and the wear is taken by flight
shoes sliding on angle track.

21
 FLIGHT CONVEYORS

For large capacities (75-125TPH)and active service a double strand roller
suspended flight conveyor with replaceable wearing parts may be selected.

These types are ideal for distribution of coal in a bunker where the length is
up to 30 metres.

Beyond that, a belt conveyor with tripper will be a better option. The pull per
chain is halved in the two strand conveyor.

Flight spacing is varied to suit the size of lumps, capacity and slope of the
conveyor.

Double strand conveyors with widely spaced flights are best for larger lumps.

This type of conveyor is equipped with strong, upright flights carried between
two chains.

To reduce friction, the bottom and sides of metal flight conveyor troughs are
often lined with Teflon.

Flight conveyors normally have two troughs One trough is on the top, with the
flights traveling in one direction, and another is directly below it, where the
flights make their return pass.

Material is often fed to the top trough from a transfer conveyor chute.

At some point, usually near an end, the top trough has openings in the
bottom.

These openings allow the material to drop down into the bottom trough.
When the material drops into the bottom trough, the flights carry it in the
opposite direction. More openings along the bottom of the lower trough allow
the material to drop into chutes for multi-point discharge.
22
 DRAG CHAIN CONVEYORS

Drag chain conveyors do not have flights, as the open links serve
to move the material.

Drag Chain conveyors where a special chain is used acts as a
scraper, may be loaded to a considerable depth. The speed is
generally low.

The trough is of cast iron or hardened face concrete with T rails
set flush.

These conveyors operate at very slow speed , usually less than 6
m/sec.

One typical application is quenching of hot material.

The trough is horizontal and filled with water, but it curves
upward toward the discharge end where the water drains
backward as the material moves up the incline.

Used for conveying broken, crushed or finely sized chips only.
Suitable for both horizontal and vertical runs.

Not used where stringy (bushy) turnings are present as these will
cause jamming of the drag chains.

The usual configuration is a rectangular trough fitted with a
single strand or two parallel strands of chain to which drag flights
are fitted to provide the conveying mechanism.
23
 EN-MASSE CONVEYORS
EN-

En-masse conveyors are essentially continuous flow conveyors
in which material moves slowly within a duct/casing as a
continuous core in contrast to the material conveyed by a screw
feeder or flight conveyor.

This is a special type of flight conveyor wherein the flights of
the lower pass completely enclosed in a closefitting tube .By
completely enclosing the flights, the conveyor can be adjusted
from horizontal to vertical, or any angle in between.

This allows great flexibility in design, and allows this type of
conveyor to be used in locations with little available space.

En-masse conveyors will handle any pulverized or granular
material unless it is highly abrasive, extremely fragile or
contains unbreakable lumps.

Since the material is in sliding contact with the walls of the
duct and is subjected to more or less squeezing, fragile material
will be pulverized to some extent. Hard lumps may jam
between the fights and casing

These conveyors are nicely suited to the materials which should
not come in contact with the lubricants, must not be
contaminated by exposure such as food products or are harmful
to breathe.
24
 CODES AND STANDARDS

IS:8599 – 1977 ; Recommendation for selection of Apron Conveyors.

IS:6834 – 1973 ; Specification for conveyor chains, chain wheels and attachments.
Part- I : Chains
Part- II :Chain wheels
Part-III :Attachments

IS: 5895 – 1985 :Specification for steel roller conveyors.

ISO/TR5047:1982 ; Continuous mechanical handling equipment – Chain Conveyors with
bearing devices or load carriers.

ISO 2140: 1975 ; Continuous mechanical handling equipment – Apron Conveyors

ISO 7189: 1983 ; Continuous mechanical handling equipment – Apron Conveyors/
Design rules

25
 SELECTION OF CHAIN CONVEYORS
Determination of main parameters
Cross sectional area of the trough is determined for a given rated throughput
capacity Q in t/hr, with account taken care of certain coefficient of trough filling by
transported material.
The volume of the load in front of the conveyor between two fights depends on
material characteristics.
For easiliy flowing materials the coefficient is 0.5-0.6 and for poorly flowing material
this is 0.7-0.8.
With the increase in angle of incline,the volume decreases.This called load factor
which is less than 1 and varies between 0.5 to 0.85.
Cross sectional area m2 of the load is threfore:
A=B(width)xH(depth)xcoef x load factor Generally 2.4-4 is the width to depth ratio.
Capacity = A x speed
Based on the above principles manufacturer’s literature have tables from which
selection of the chain conveyor can be made.
Some manufacturer’s have nomograms for easy selection.

26
 SELECTION OF CHAIN CONVEYORS

27
 SELECTION OF CHAIN CONVEYORS

28
 CONCLUSION

THANK YOU

29