Express Tunnel Conveyor Chain

Understanding Conveyor Chains

If you have questions about your conveyor chain setup or any of our conveyor chain parts, you can contact us directly. For some useful insight right now, read through this brief overview!

How Does a Conveyor Chain Work?

A conveyor chain operates by linking together a series of metal links to form a continuous loop that moves along a set path. Each link is joined by a pin, which allows for flexibility and ensures the chain can bend smoothly around sprockets installed at various points along the conveyor system. The motor-driven sprockets grip the chain’s links, pulling the entire assembly forward and guiding vehicles or materials through the wash tunnel or processing area. Supporting components like side links and carrier links help distribute the load evenly, preventing excess strain on any single part of the chain. In car wash applications, this mechanism ensures vehicles are moved consistently from entry to exit, despite water, chemicals, or debris that would otherwise cause friction or slippage on a belt-driven system.

Typical Parts of a Conveyor Chain

Typically, conveyor chains are made up of several essential components that work together to move vehicles through a tunnel car wash smoothly and reliably.

• The main parts begin with the chain itself, which is typically constructed of interconnected metal links that form a continuous loop.
• These links are joined together by pins—such as cotter and clevis pins—that maintain alignment and ensure flexibility as the chain navigates around sprockets.
• Sprockets, mounted along the conveyor line, provide the necessary drive and support to move the chain forward. A sprocket on a conveyor belt is essentially a toothed wheel specifically designed to engage with the conveyor chain or belt, helping to drive and guide it along the designated path.
• Side links and carrier links are also crucial, as they reinforce the chain’s strength and help distribute weight evenly.
• M2 links and specialty connector pieces allow for replacement of specific worn sections without requiring a complete overhaul, saving both time and money.

Another consideration to be made are the five parts of a roller chain. So, what are the five parts of a roller chain?

1. The first component is the inner link, which forms the foundational structure of the chain and houses the rollers.
2. Next is the outer link, connecting the chain sections and providing stability during operation.
3. The third part is the pin, which passes through both the inner and outer links, holding the assembly together and allowing the chain to flex as it moves around sprockets.
4. The fourth element is the bushing, sitting inside the inner link and providing a surface for the pin and roller to rotate around, minimizing friction and wear.
5. Finally, the roller itself sits on the bushing, allowing for smooth movement over sprockets and enhancing the chain’s lifespan.

Types of Conveyor Chains

The most common types of conveyor chains include roller chains, engineered steel chains, and welded steel chains.

• Roller chains are widely used for lighter-duty operations, providing a smooth and flexible option for moving vehicles through shorter or less demanding wash tunnels.
• Engineered steel chains are built to handle heavy loads and frequent cycles, making them ideal for high-traffic tunnel systems and express washes that need to process many vehicles each day.
• Welded steel chains are favored in harsh environments due to their robust design and enhanced resistance to wear, water, and chemicals—qualities that are critical in car wash tunnels where the chain is constantly exposed to moisture and detergents.

Each chain type is available in various sizes and configurations, allowing operators to match their specific conveyor system requirements and achieve optimal reliability.

What is the Strongest Roller Chain?

Among standard roller chains, options manufactured from premium alloy steel and engineered with heat-treated components provide exceptional tensile strength and long-term durability. For heavy-duty car wash conveyors and high-capacity industrial systems, chains like the D88K and other engineered steel models are regarded as some of the strongest in routine operation. These chains are designed to withstand frequent cycles, constant moisture, and chemical exposure—factors that typically wear down lighter-duty models much faster.

Common Materials and Specifications for Metal Conveyor Chains

Most conveyor chains are made from high-grade carbon steel or stainless steel, both chosen for their durability and resistance to corrosion. Stainless steel chains offer excellent protection against rust when exposed to constant water and harsh chemicals, making them a top choice for tunnel and in-bay automatic systems where moisture is inevitable.

In addition to the base material, chains may feature specialized coatings or treatments, such as zinc plating or case hardening, which further increase their resistance to corrosion and wear. It’s also crucial to check the load rating, pitch size, and link dimensions to ensure proper fit and reliable operation with your conveyor’s sprockets and guides. By understanding these specifications—like tensile strength, material grade, and pin diameter—you can choose chains that match the needs of your particular system. Here's a quick rundown of buzzwords to keep in mind for conveyor chains:

• Size
• Pitch
• Roller Diameter
• Inside Width
• Pin Diameter
• Pin Inside Diameter
• Pin Length
• Side Plate Height
• Side Plate Thickness
• Chain Weight

Understanding Chain Size: 40 vs 41, or 50 vs 60

Chain sizes like 40, 41, 50, and 60 refer to standardized dimensions commonly used in industrial and wash tunnel conveyors. The primary difference between these sizes lies in their pitch—the distance between the centers of two consecutive pins—and the overall width of the chain.

For example, a #40 chain has a pitch of 0.5 inches, while a #41 chain offers a similar pitch but a narrower profile, making it suitable for lighter loads or more compact conveyor designs. On the other hand, #50 and #60 chains feature larger pitches and increased strength, making them ideal for heavy-duty tunnel systems where they need to withstand higher vehicle weights and more demanding conditions.

What's the easiest way to measure conveyor chain size? Start by identifying the pitch of the chain, which is the distance from the center of one pin to the center of the next pin. Use a ruler or caliper to measure this distance accurately—most standard chains will fall into common measurements like 0.5-inch or 0.625-inch pitch. Next, determine the roller diameter and the width between inner plates, as these dimensions help confirm you have the right chain profile for your equipment. It’s important to clean the chain before measuring to avoid debris affecting your measurement.

Applications of Conveyor Chains Across Industries

• In the automotive sector, conveyor chains are critical for assembly lines and parts transport, providing consistent, synchronized movement for high-speed production.
• Food processing plants use specialized conveyor chains designed to handle sanitation and the demands of wet or corrosive environments.
• Manufacturing facilities of all types rely on conveyor chains to transport raw materials, components, and finished products, helping to streamline production workflows and reduce manual labor.
• In the laundry and janitorial sectors, similar chain designs can be found driving automated systems that move linens, supplies, and equipment throughout facilities.

Actionable Maintenance Tips for a Chain Conveyor

• Start by scheduling regular inspections to check for signs of wear, corrosion, or misalignment on the chain and its components.
• Lubricate moving parts with the recommended oil or grease to minimize friction and reduce the risk of premature failure, especially since car wash conveyors face constant exposure to water and chemicals.
• Monitor chain tension to ensure it remains within the manufacturer’s specified range; excess slack can cause the chain to jump sprockets, while over-tightening can lead to unnecessary strain and accelerated wear.
• Replace any damaged or excessively worn pins, links, or sprockets immediately, as even minor defects can quickly escalate into larger issues that impact system efficiency.
• Keep conveyor guides, sprockets, and drive mechanisms clean and free of debris to prevent buildup that could interfere with smooth chain movement.
• Finally, always keep an inventory of critical replacement parts—such as extra chain links, pins, and sprockets—on hand so you can quickly address maintenance needs and minimize downtime, ensuring your car wash runs reliably day after day.

When to Replace a Cam Chain or Roller Chain

Cam chains and roller chains should be carefully monitored for signs of stretching, wear, or damage, as these issues can lead to misalignment and sudden failure if not addressed promptly. In a car wash conveyor, replace the chain if you notice excessive slack, uneven movement, or visible signs of corrosion and pitting on the links or pins. Moreover, if inspections reveal missing or damaged rollers, bent links, or if the chain begins to jump or skip teeth on the sprocket, it’s time to consider replacement to maintain safe and reliable operation. Since frequent exposure to water, chemicals, and grit accelerates wear in tunnel systems, establishing a regular maintenance schedule is crucial.