The Right Chain Tension: Prevent Wear and Downtime

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Is your chain too tight or too loose? Both situations can cause major problems. A chain that is too tight increases friction and wear, while a chain that is too loose can skip or even derail from the sprocket. Fortunately, you can prevent this by properly adjusting the chain tension. In this article, you will read how to do this and why proper chain tension is essential for optimal machine performance.

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The Influence of Chain Tension on the Operation of Your Machine

Chain tension determines how tightly the chain runs over the sprockets. If too tight, friction between pin and bushing increases, causing stress, faster wear, higher energy use, and potential chain damage. If too loose, the chain may misalign, derail, or cause machine damage and downtime. Proper tension ensures smooth operation, reduces wear, and improves machine reliability. But how do you determine the correct chain tension?

The Right Chain Tension for Optimal Performance

Determining Chain Tension Based on Slack

The ideal slack is approximately 1% of the center-to-center distance between the shafts, with a maximum of 3%. This prevents excessive stress on the links and sprockets, thereby reducing wear and energy consumption.

Calculating Chain Tension

If it is not possible o measure the slack of the chain, you can also calculate the pretension based on the actual tensile force. The ideal pretension is 10 percent of the actual tensile force. The actual force can be calculated as follows:
Actual force (N) = (Used power (Watts)) / (Speed (m/s))

Manually Determining Chain Tension

If exact chain tension can’t be calculated, it can be judged by feel. Start by checking the current tension and adjusting the shaft or tensioner—manual or automatic—step by step. Test frequently to ensure the chain moves smoothly over the sprockets. Apply light pressure to check: the chain should move freely but not sag or hit the sprockets. Once the tension feels right, run the machine at low speed to check for stability, vibrations, or noise.

Since chains stretch over time, regular tension checks and maintenance are key to a long-lasting, reliable system.

Factors in choosing the right drive chain

Regularly tightening the chain prevents unnecessary wear and extends the life of the machine. By periodically checking and adjusting the tension, the chain continues to function well and unexpected failures are prevented. In addition to tension, lubrication plays a major role in maintaining a well-functioning chain. By using the right lubricants, friction is reduced and the chain continues to run smoothly. Check out our oil and lubrication brochure for specific maintenance instructions and the right lubricants for your application. Every machine and application is different. That’s why it’s important to choose a chain that perfectly fits your situation. Our experts are happy to help you make the right choice.

Donghua’s Added Value

At Donghua, we understand how important it is to maintain the correct chain tension for the performance and longevity of your machine. That’s why we offer customized solutions specifically tailored to your needs.

Our experts assist you in selecting the right chain and support you in optimizing the tension. This not only helps to extend the lifespan of your machines but also reduces maintenance costs and increases the reliability of your systems.

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