In an assembly line of a French car manufacturer, the reliability of part feeding became increasingly a problem in the past, because the conveyor chain had too high wear and thus the system stopped again and again. The company has now almost completely eliminated downtime in its conveyor lines by installing the "Double-Plus" chain of Tsubaki reached.
When talking about production lines in the automotive industry, many initially think of robot arms that lift, merge and assemble body parts and car components. In addition, there are a variety of small parts that are just as important for the construction of a vehicle. All parts have one thing in common: they must be reliably transported to the appropriate assembly stations.
The problem to be solvedNormally, the many different small parts are loaded into boxes and fed on conveyor belts to the assembly stations. In order for the operation to run smoothly, a reliable transport system for the boxes is indispensable. Especially in the automotive industry would otherwise incur unacceptable costs for downtime.
In the assembly line of the French car manufacturer, the reliability of part feeding has become more and more of a problem in the past: the line consists of a conveyor line that runs through the entire production area. At certain points - especially at the accumulation or accumulation conveyor stations - there was an increasing friction between the crate and the conveyor system, which led to increased wear of the conveyor chain. The downtime caused and to reduce this, the maintenance costs increased. The originally intended production efficiency was noticeably impaired.
A chain as a solution providerThe motorist turned to Tsubaki, asking to inspect the conveyor. The desired solution should provide long-term reliability and improved performance. The leading manufacturer of drive technology products recommended its robust "Double-Plus" conveyor rollers for this application. The material boxes in the production line can now be transported from A to B without wear. They are extremely resistant to wear even if there is a high degree of friction of the small parts located on the conveyor belt.
Two diameters for fast and slowThe special design of the Double-Plus chain is based on two rollers with different diameters that rotate around a common bolt. A large center roller carries the boxes, while a smaller, outwardly projecting roller holds the chain in the guide rail. As the rollers rotate, the different diameters result in different speeds. 2,5 spins the bigger part faster than the smaller one. As a result, the boxes also experience a higher conveying speed than the chain. This burdens the conveyor system less and reduces its wear.
The double plus chain is available in five sizes with the pitch dimensions 19,05, 25,40 31,75, 38,1 and 40,08 mm as well as in different material versions. The manufacturer recommends the carbon steel chains for standard applications or, if required, a maintenance-free or stainless steel version. Provided with an integrated cover, the conveyor chain is suitable for use in such conveyor systems where small parts such as screws or nuts can fall into the gaps between the guides and rollers.
All's well that ends wellThe car manufacturer advised by Tsubaki reported an immediate improvement of the conveying process following the installation of the Double-Plus chain. The wear was minimized and the service life and reliability in operation could be significantly improved. But that's not all: the conveyor speed of the boxes and thus the efficiency in production could also be increased. As a pleasant side effect, the noise emission during operation was also reduced.