SPROCKET AND CHAIN DRIVE:

This is a cycle chain sprocket. The chain sprocket is coupled with another

generator shaft. 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:

1. Sprockets have many engaging teeth; gears usually have only one or two.
2. The teeth of a gear touch and slip against each other; there is basically no slippage in a

sprocket.
3. The shape of the teeth is different in gears and sprockets.

Figure Types of Sprockets

Engagement with Sprockets:

Although chains are sometimes pushed and pulled at either end by cylinders,

chains are usually driven by wrapping them on sprockets. In the following section, we

explain the relation between sprockets and chains when power is transmitted by

sprockets.

1. Back tension
 First, let us explain the relationship between flat belts and pulleys. Figure 2.5

shows a rendition of a flat belt drive. The circle at the top is a pulley, and the belt hangs

down from each side. When the pulley is fixed and the left side of the belt is loaded with

tension (T0), the force needed to pull the belt down to the right side will be:

T1 = T0 3 eµu

For example, T0 = 100 N: the coefficient of friction between the belt and pulley, µ

= 0.3; the wrap angle u = ¼ (180).

T1 = T0 3 2.566 = 256.6 N

In brief, when you use a flat belt in this situation, you can get 256.6 N of drive

power only when there is 100 N of back tension.

For elements without teeth such as flat belts or ropes, the way to get more drive

power is to increase the coefficient of friction or wrapping angle. If a substance, like

grease or oil, which decreases the coefficient of friction, gets onto the contact surface, the

belt cannot deliver the required tension.

In the chain's case, sprocket teeth hold the chain roller. If the sprocket tooth

configuration is square, as in Figure 2.6, the direction of the tooth's reactive force is

opposite the chain's tension, and only one tooth will receive all the chain's tension.

Therefore, the chain will work without back tension.

 Figure Flat Belt Drive

Figure Simplified Roller/Tooth Forces

 Figure The Balance of Forces Around the Roller

But actually, sprocket teeth need some inclination so that the teeth can engage and

slip off of the roller. The balances of forces that exist around the roller are shown in

Figure 2.7, and it is easy to calculate the required back tension.

For example, assume a coefficient of friction µ = 0, and you can calculate the back

tension (Tk) that is needed at sprocket tooth number k with this formula:

Tk = T0 3 sin ø k-1 sin(ø + 2b) Where:

Tk= back tension at tooth k
T0 = chain tension
ø= sprocket minimum pressure angle 17 64/N(š)
N= number of teeth
2b = sprocket tooth angle (360/N)
k= the number of engaged teeth (angle of wrap 3 N/360); round down to the nearest

whole number to be safe

By this formula, if the chain is wrapped halfway around the sprocket, the back

tension at sprocket tooth number six is only 0.96 N. This is 1 percent of the amount of a

flat belt. Using chains and sprockets, the required back tension is much lower than a flat

belt.

Now let's compare chains and sprockets with a toothed-belt back tension.

Although in toothed belts the allowable tension can differ with the number of

pulley teeth and the revolutions per minute (rpm), the general recommendation is to use

1/3.5 of the allowable tension as the back tension (F). This is shown in below Figure 2.8.

Therefore, our 257 N force will require 257/3.5 = 73 N of back tension.

Both toothed belts and chains engage by means of teeth, but chain's back tension is

only 1/75 that of toothed belts.

 Figure 2.8 Back Tension on a Toothed Belt

Chain wear and jumping sprocket teeth

The key factor causing chain to jump sprocket teeth is chain wear elongation (see

Basics Section 2.2.4). Because of wear elongation, the chain creeps up on the sprocket

teeth until it starts jumping sprocket teeth and can no longer engage with the sprocket.

Figure 2.9 shows sprocket tooth shape and positions of engagement. Figure 2.10

shows the engagement of a sprocket with an elongated chain.

In Figure 2.9 there are three sections on the sprocket tooth face:

a: Bottom curve of tooth, where the roller falls into place;

b: Working curve, where the roller and the sprocket are working together;
c: Where the tooth can guide the roller but can't transmit tension. If the roller, which

should transmit tension, only engages with C, it causes jumped sprocket teeth.
 The chain's wear elongation limit varies according to the number of sprocket teeth

and their shape, as shown in Figure 2.11. Upon calculation, we see that sprockets with

large numbers of teeth are very limited in stretch percentage. Smaller sprockets are

limited by other harmful effects, such as high vibration and decreasing strength;

therefore, in the case of less than 60 teeth, the stretch limit ratio is limited to 1.5 percent

(in transmission chain).

Figure 2.9 Sprocket Tooth Shape and Positions of Engagement

 Figure 2.10 The Engagement Between a Sprocket and
  an Elongated Chain

Figure 2.11 Elongation Versus the Number of Sprocket Teeth

In conveyor chains, in which the number of working teeth in sprockets is less than

transmission chains, the stretch ratio is limited to 2 percent. Large pitch conveyor chains

use a straight line in place of curve B in the sprocket tooth face.

A chain is a reliable machine component, which transmits power by means of tensile

forces, and is used primarily for power transmission and conveyance systems. The

function and uses of chain are similar to a belt. There are many kinds of chain. It is

convenient to sort types of chain by either material of composition or method of

construction.

We can sort chains into five types:

Cast iron chain.

Cast steel chain.

 Forged chain.

Steel chain.

Plastic chain.

Demand for the first three chain types is now decreasing; they are only used in

some special situations. For example, cast iron chain is part of water-treatment

equipment; forged chain is used in overhead conveyors for automobile factories.

In this book, we are going to focus on the latter two: "steel chain," especially the

type called "roller chain," which makes up the largest share of chains being produced,

and "plastic chain." For the most part, we will refer to "roller chain" simply as "chain."

NOTE: Roller chain is a chain that has an inner plate, outer plate, pin, bushing, and roller.

In the following section of this book, we will sort chains according to their uses,

which can be broadly divided into six types:

1. Power transmission chain.

2. Small pitch conveyor chain.

3. Precision conveyor chain.

4. Top chain.

5. Free flow chain.

 6. Large pitch conveyor chain.

The first one is used for power transmission; the other five are used for

conveyance. In the Applications section of this book, we will describe the uses and

features of each chain type by following the above classification.

In the following section, we will explain the composition of power transmission

chain, small pitch chain, and large pitch conveyor chain. Because there are special

features in the composition of precision conveyor chain, top chain, and free flow chain,

checks the appropriate pages in the Applications section about these features.

Basic Structure of Power Transmission Chain

A typical configuration for RS60-type chain is shown in Figure 1.1.

 Figure 1.1 The Basic Components of Transmission Chain

Connecting Link

This is the ordinary type of connecting link. The pin and link plate are slip fit in

the connecting link for ease of assembly. This type of connecting link is 20 percent lower

in fatigue strength than the chain itself. There are also some special connecting links

which have the same strength as the chain itself. (See Figure 1.2)

Tap Fit Connecting Link

 In this link, the pin and the tap fit connecting link plate are press fit. It has fatigue

strength almost equal to that of the chain itself. (See Figure 1.2)

Figure 1.2 Standard Connecting Link (top)

  and Tap Fit Connecting Link (bottom)

Offset Link

An offset link is used when an odd

number of chain links is required.

It is 35 percent lower in fatigue

strength than the chain itself. The

pin and two plates are slip fit.

There is also a two-pitch offset

link available that has fatigue strength as great as the chain itself. (See Figure 1.3)
Figure 1.3 Offset Link