1. Feed machinery equipment accessories sprocket product introduction
In many aspects of feed production, the conveying of materials and the stable operation of the transmission system are very important. Sprocket, as a key transmission component, is widely used in the chain transmission of feed machinery equipment. It works with the chain to transfer the power from one axis to another, which realizes a variety of functions in the feed production process, such as raw material transportation and mixing device driving.
2. Structural characteristics
Wheel structure
The wheel body of the sprocket is usually a circular disk-like structure, and its thickness varies according to the load and application scenario. In general, in the main transmission sprockets of feed transmission that bear large tension and torque, the thickness of the wheel body is relatively large to ensure sufficient strength and stiffness. A series of toothed structures are uniformly distributed along the outer edge of the wheel body, which is the key part of meshing with the chain. The shape, size and precision of tooth shape directly affect the meshing effect of sprocket and chain and the smoothness and efficiency of transmission. Common sprocket tooth shape has standard tooth shape and special tooth shape, standard tooth shape such as involute tooth shape, has good transmission performance and versatility, can adapt to most chain mesh requirements; Special tooth profiles are customized according to specific feed machinery design needs and chain specifications, for example, in some high-speed or heavy-duty feed production equipment, sprockets with optimized tooth profiles may be used to improve transmission efficiency and reduce wear.
Hub and spoke
The hub is located in the center of the sprocket and is the part connected with the shaft. The inner diameter of the hub matches the diameter of the shaft, usually using interference fit, key connection or spline connection, etc., to ensure that the sprocket can be firmly installed on the shaft and rotate in sync with the shaft. The length of the hub also needs to be designed according to the stress of the shaft and the installation requirements, generally in the case of heavy load or axial force, the hub length is longer to increase the stability of the connection. The spoke is the part that connects the hub and the wheel body, and its role is to transfer the load borne on the wheel body to the hub and disperse it to the shaft. The structure of the spoke is varied, common plate spoke, spoke type spoke and so on. The plate spoke is simple in structure and easy to manufacture, which is suitable for sprockets of general load and speed. Spoke spoke has better ventilation and heat dissipation performance and light weight, in some high-speed or high heat dissipation requirements of feed machinery sprockets are more used, such as the stirring shaft sprocket in the feed mixer, the spoke spoke can effectively reduce the heat accumulation caused by high-speed rotation, improve the service life of the sprocket.
Alveolar and apex
The sprocket groove is the part where the chain roller is embedded and rolled, and the shape and size of the groove should be matched with the diameter and pitch of the chain roller. The bottom of the tooth groove is usually designed with a certain arc transition to reduce the impact and friction of the chain roller when entering and exiting the tooth groove. The top of the tooth is the top part of the tooth shape, and the height and shape of the top of the tooth play an important role in preventing chain decoupling and ensuring the smoothness of the transmission. When designing the top of the tooth, it is necessary to take into account the lateral swing and tension changes of the chain, and generally set a certain chamfering or rounding at the top of the tooth, so that the chain can transition smoothly during operation, and avoid chain stagnation or damage due to the sharp top of the tooth.
3. Material characteristics
Carbon steel
Carbon steel is one of the commonly used materials for the manufacture of sprockets, such as 45 steel. Carbon steel has a high strength and a certain toughness, after appropriate heat treatment, can meet the general feed machinery equipment sprocket performance requirements. After tempering treatment, the hardness of No. 45 steel can reach HB217-255, which makes it have good wear resistance and fatigue resistance under moderate load and speed. The sprocket in the small feed conveying equipment or auxiliary transmission device is made of 45 steel, which can reduce the manufacturing cost and has a high cost performance under the premise of ensuring the performance. For example, in the raw material processing workshop of some feed mills, the sprocket on the chain conveyor used to transport raw materials such as grains, the 45 steel sprocket can run stably, effectively transfer the power to the chain, and achieve the smooth transmission of raw materials.
Alloy steel
For large, heavy duty or feed machinery and equipment sprockets operating in harsh working environments, alloy steel is more suitable. For example, 40Cr alloy steel contains chromium, which can improve the hardenability and strength of the steel. After tempering and surface quenching treatment, the surface hardness can be significantly increased, up to HRC50-55, which makes the sprocket under huge torque, tension and impact loads have excellent wear resistance and fatigue resistance. In the main drive sprocket of large feed pelleting machine or in the feed mixer mixing shaft sprocket working in high temperature and high humidity environment, 40Cr alloy steel sprocket can run stably for a long time, reduce equipment failure caused by wear, deformation or fatigue fracture, and ensure the continuity and reliability of feed production. In addition, some special alloy steel such as 35CrMo, its comprehensive performance is more excellent, in the high temperature, high pressure environment can still maintain good mechanical properties, suitable for some special process requirements of the feed production equipment in the sprocket, such as the key drive sprocket of the feed extruding machine.
Stainless steel
In the feed production environment with high health requirements, such as aquatic feed or pet feed processing workshop, stainless steel sprockets are widely used. For example, 304 stainless steel has good corrosion resistance and oxidation resistance, which can effectively prevent the water, acid and alkali components in the feed and the erosion of the sprocket by microorganisms, ensure the long-term stable operation of the sprocket, and also avoid the pollution caused by the corrosion of the sprocket to the quality of the feed products. The stainless steel sprocket also has a better surface finish, which is conducive to reducing the coefficient of friction between the chain and the sprocket, improving transmission efficiency, and is also more in line with the requirements of the food grade or sanitary production environment in appearance. In some high-end pet feed production lines, all sprockets in contact with the feed or in the feed production area are made of 304 stainless steel to ensure the quality and safety of pet feed.
4. Manufacturing process
Forged blank
The blank of sprocket is usually prepared by forging process. Forging can refine the grain of the metal material and make the organization more dense, thereby improving the strength and toughness of the material, and eliminating the internal defects caused by the metal in the smelting process. For the alloy steel sprocket blank, the forging process is particularly important, which can make the alloying elements evenly distributed in the steel matrix and give full play to the strengthening effect of alloying elements. The blank after forging needs to be normalized or annealed to eliminate the forging stress, improve the cutting performance of the material, and lay a good foundation for the subsequent machining process. For example, for 40Cr alloy steel sprocket blanks, normalizing treatment after forging can homogenize the organization, moderate hardness, and facilitate turning, milling and other processing operations.
machining
Machining is the key link of sprocket manufacturing, including turning, milling, drilling, boring, grinding and other processes. First, through the turning process, the outer circle, inner hole and end face of the blank are processed to the design size, and the basic shape of the wheel hub and spoke is processed. In the process of turning, it is necessary to strictly control the cylindricity of the wheel body, the coaxiality of the wheel hub and other accuracy indicators, as well as the dimensional accuracy and surface roughness of each part. For example, the cylindricity error of the wheel body is generally required to be controlled within a very small range to ensure the smoothness of the sprocket during rotation. Then the milling process is used to process the tooth shape of the sprocket. According to the design requirements, the appropriate milling cutter and milling process are selected to accurately process the tooth groove, tooth tip and other parts to ensure that the shape accuracy and dimensional accuracy of the tooth shape meet the standard or customized requirements. Drilling and boring processes are used to process features such as keyways and mounting holes on the hub to ensure the accuracy of the connection with the shaft and other components. Finally, the key mating surface of the sprocket, such as the inner hole and outer circle of the wheel hub, can be refined by grinding process to further improve its surface accuracy and finish, ensuring stability and reliability after installation. In the whole machining process, it is necessary to use high-precision machine tool equipment and advanced tools, and operate in strict accordance with the process specifications to ensure the manufacturing quality of the sprocket.
5. Performance characteristics
Efficient transmission performance
The sprocket is combined with the chain to achieve efficient power transmission. Its tooth shape design and manufacturing accuracy ensure good meshing with the chain, making the power loss in the transmission process is small, and the transmission efficiency is high. In feed production equipment, whether it is to drive the rotation of the conveyor chain or the mixing device, the sprocket can stably transfer the power of the motor or other power source to the working parts to ensure the normal operation of the equipment. For example, in a large feed conveying system, the main drive sprocket drives a long conveyor chain, transporting a large number of feed raw materials from one process to another, and its efficient transmission performance ensures the continuity and stability of the transmission, improving the efficiency of feed production.
Good carrying capacity
Due to the use of high-quality materials and reasonable structural design, the sprocket has a strong bearing capacity. It can withstand large tensile force, torque and impact load, in the operation of feed machinery and equipment, even in the face of complex stress situations, such as in the feed crusher, the uneven resistance and impact generated when crushing materials, sprockets can also stably support and transfer power, will not easily deformation, fracture or damage, to ensure the safe operation of equipment and the continuity of production. For example, the main drive sprocket of the large feed granulator needs to withstand the huge torque and axial force in the process of making the grain, and its good carrying capacity ensures the stable operation of the granulator and the production of high-quality feed particles.
Stable operation characteristics
The high precision manufacturing process and good balance performance of the sprocket make it have stable operating characteristics when rotating at high speed. Factors such as the cylindricity of the wheel body, the accuracy of the tooth shape and the coaxiality of the wheel hub and the wheel body ensure that the sprocket will not produce excessive vibration and unbalanced force during the rotation process, and reduce the impact on other parts of the equipment, such as the wear of the chain and the fatigue of the bearing. In the feed mixer, the stable sprocket can make the mixing shaft evenly stir the material, improve the mixing effect, reduce the noise and energy consumption of the equipment, and extend the service life of the equipment.
6. FAQ
Q: What is the main material of the sprocket?
A: Sprockets are usually made of high-strength steel or alloy steel to ensure that they have sufficient strength and wear resistance. These materials can withstand high loads and long periods of use.
Q: What are the surface treatment processes of sprockets?
A: Common surface treatment processes for sprockets include quenching, carburizing and nitriding. These processes can improve the hardness and wear resistance of the surface and extend the service life.
Q: What problems may occur during the use of the sprocket?
A: The sprocket may have problems such as wear, fracture, deformation or poor fit during use. These problems are usually caused by overload, inadequate lubrication, or material defects.
Q: How long is the sprocket replacement cycle?
A: The replacement cycle of the sprocket depends on the frequency of use, the working environment and the operating condition of the equipment. In general, when significant wear, deformation or inability to effectively drive is found, a new sprocket should be considered.
Q: What are the heat treatment processes of sprockets?
A: The heat treatment process of the sprocket includes quenching, tempering and normalizing. These processes can improve the mechanical properties of the material, increase its hardness and wear resistance, and thus extend the service life of the sprocket.
