Novel lubrication system extends chain life

The consequences of not properly applying lubrication can be expensive. Inadequately lubricated chains wear down with alarming speed and lead to costly downtime and replacement. Over-lubrication can be almost as big a problem, as it can encourage the chain rollers to slide, causing flat spots, meaning the rollers will not roll properly and evenly. Of course, lubrication-free chains are available to counter these problems, but these are both significantly more expensive than their conventional counterparts and are by no means suitable or desirable in all applications. The conventional methods of lubricating chains – drip feed, manual application, brush application and spit/spray systems have varying degrees of success and can struggle to hit the right spot, especially when chain speeds fluctuate. It was with this in mind that the idea for the Rotalube Chain Lubrication system was developed. The Rotalube is essentially a controlled applicator that does not suffer from excessive wear, and maintains accurate lubrication whatever the condition of chain. Its inventor, Dave Chippendale of Blackburn-based BKC Products, took the idea to leading UK lubrication specialist Interlube, which is now manufacturing, distributing and selling it. Essentially, the idea revolves around a porting system that meters lubricant through precision ejectors incorporated within the sprocket assembly. Although simple in principle, the process is relatively complex, as the interaction from the chain rotates the sprocket applicator and when the ports align within the sprocket body, the pressure within the system overcomes the back pressure of the ejector nozzles. This results in lubricant delivered onto the link plates of the chain precisely and reliably. From then on the science of capillary action takes over and results in a perfectly lubricated chain that – crucially – extends chain life. According to Keith Horner of Interlube, Chippendale developed the system out of sheer frustration with existing methods. He says: "His basic idea was to come up with a better method than manual, drip, spray or brush. Most of those are fundamentally flawed. Manual methods are subject to human error, brushes deteriorate and drip or spray methods are often erratic as they rely on the nozzles being properly positioned and maintained to ensure that lubrication fluid isn't just being fired into thin air." Chippendale and Interlube have been working on the Rotalube concept for the last two years. Interlube has developed a new, low-cost ACR pump specifically to operate with standard Rotalube applicators. The 24V DC ACR pump has fully-adjustable run and dwell settings and is pre-programmed to open and shut a solenoid valve that will allow air to mix with the metered oil output from the pump. The system can be used throughout the food, automobile, steel, fibreglass and cement industries. Typical applications that can benefit include food processing machines, industrial dryers, tissue converting factories, waste paper conveyors, truck manufacturing plants, escalators and elevators. According to Horner, interest is already considerable from several quarters. He says: "Because it's so different to the standard methods of lubrication, it's attracting a great deal of interest. We've got about a dozen systems installed and working now – some in fairly large-scale, high-profile companies. Judging from the savings they're making, we're very optimistic."