Tsubaki's self-lubricating conveyor chains avoid contamination in sensitive environments and save of maintenance costsIn today's demanding industrial and process environments, lubrication is increasingly becoming a luxury that can no longer be afforded. For years conventional oil based lubricants have not been used in food environments because of the likelihood that they may contaminate the product. But now the same demands for cleanliness are spreading, or have spread, into other industry sectors.
Paper, packaging, electronics, white and brown goods manufacture are all areas where this is so.
Contamination of the final product from oil spillage or oil mist is a major reason for the lube-free demand in these sectors.
But not exclusively so.
There are other important considerations, including the observance of Health and Safety regulations, the cost of the lubricants themselves - and the down-line costs of their disposal.
In addition, if lubrication can be avoided altogether then planned lubrication intervals are unnecessary and maintenance costs are reduced accordingly.
One product in particular where removing the requirement for lubrication and maintenance is particularly important is chain.
Normally all chains must be thoroughly lubricated to extend their life.
Most chain manufacturers' issue lubrication recommendations, and most maintenance personnel understand the importance of lubrication.
However, there is often a gap between what is understood and what is done.
Regular observation of chains, it is true, provides assurance that automated lubrication systems are effective, or that manual lubrication schedules are being carried out.
But, the thoroughness with which this is executed is often open to question: especially so if the chain is inaccessible, on an overhead conveyor for example.
The demand for chains, which operate without lubrication and are essentially maintenance free, has resulted in technological innovation of a basic product, which in outward appearance has changed relatively little since its invention by Leonardo Da Vinci in the 15th century.
The result of this innovation is that lube-free chains are now in the mainstream of industrial manufacturing and can replace conventionally pre-lubricated chains in the majority of applications, in many cases with enhanced load and life expectancy advantages.
There are a number of ways of achieving non-lube performance of drive chains.
These vary with the load capacity and life requirements of the transmission medium.
Today engineering plastics, especially self-lubricating acetyl types, play a part but, in the main, these type of chains suit applications where corrosion resistance and weight saving are more important than load capacity.
The first generation of what we will call mainstream lube-free chains (i.e to replace standard chains) were units with oil sealed in via O-rings.
This design has continued and is still in use today.
Although generally effective, it does suffer from a number of serious drawbacks.
Firstly, while being referred to as 'non-lube', the chain does normally require external lubrication to prevent the O-rings from drying up and, subsequently, falling out.
Secondly, the wear life of the chain depends upon the life span of the O-ring.
Thirdly, friction between O-Rings and the chain link plates tends to make it difficult for the chain to bend and articulate.
Lastly, users sacrifice energy because more power is required to operate their drive systems.
It was to overcome these problems that Tsubaki developed its first Lambda design, in 1978.
Today, the chain is into its third generation and is offering users wear life 14 to 40 times greater than that of standard roller chains (depending on speed), with the added benefit of greatly reduced elongation.
Tsubaki's continuous development of the chain has also led to the introduction of special versions such as X-Lambda, an ultra long life, lube-free chain that provides at least 10 times the working life of conventionally sealed 'O' ring chains without any significant loss of transmission efficiency.
The performance of Lambda is the result of a construction, which comprises specially sintered, oil impregnated bushings, coated pins and extra durable rollers.
The durable rollers facilitate super smooth engagement on the sprocket for longer periods of time.
This significantly reduces sprocket wear.
Moreover, the smooth articulation of chain and sprocket reduces power transmission losses by a high order.
Importantly, the Lambda self-lube design is able to lubricate not only between chain and bushing but also between bushing and roller.
This means that Lambda chain is uniquely suitable for both drive and conveyor applications where roller inner wear is a problem.
Lambda is especially suitable for 'clean' operations where machines and conveyed materials must be free of lubricants, or where lubrication is difficult or impossible due to limited access.
Such conditions are routinely encountered in food processing, printing, packaging and textile applications.
Engineering plastics come into their own in chain designs where non-lube performance is essential, but the maximum loads and the maximum chain tension required are less than those for standard roller chain.
The resistance that plastics naturally possess to corrosion is also an important factor in their use.
Tsubaki uses engineered plastic sleeves between the pins and bushings of its Plastic Sleeve chain.
The self-lubricating properties of the engineering plastic sleeves increase the wear life of Tsubaki Attachment Chains, RS Roller Chains and Stainless Chains, while removing any risk to products and the working environment of contamination from lubrication oils.
The design of the chains, with plastic rollers, also eliminates any contamination from metal dust.
In applications where stainless steel plastic sleeve chain is applied, rust preventative and lubrication are unnecessary, so these working environments also stay clean and sanitary.
Engineering plastic is also the material used for the inner links on Tsubaki 's Poly Steel chain.
Poly-Steel chains are lube-free chains used in power transmission and conveying applications in the production of food or medicines.
They have no rollers.
Instead they rely upon the self-lubricating properties of the plastic from which their inner links are made.
The wear resistance of these chains is higher than that of stainless steel roller chains without lubrication.
Poly-Steel chain has the advantage of being 50% lighter than all-stainless steel chain, which gives easier handling and installation; in addition, corrosion resistance is also greater than that of all-metal chain.