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Sprockets

Sprockets are used to transfer power to conveyor chains. Simply put, they are wheels that have teeth that match with a conveyor chain to transmit motion. They come in single, double and up to quintuple formats. Usual specifications for conveyor sprockets are teeth number, bore diameter, hub diameter, outside diameter, hub one side or both, length-through bore and weight.

Choice of material selection depends on transmission of power and speed, operating temperature, exposure to corrosive environments and noise factors.

Components of a Sprocket
Chain or Belt

The sprocket teeth are critical components that engage with the bushings or rollers of a conveyor chain. As the sprocket rotates, the teeth exert a pulling force on the chain in the direction of rotation. The quantity of teeth is determined by the sprockets outside diameter (OD), which should be calculated based on the chain’s pitch and load requirements. It is noteworthy that when a sprocket has an even number of teeth, the same tooth will consistently engage with the same rollers upon each complete rotation, potentially leading to accelerated wear. Conversely, utilizing an odd number of teeth enhances the service life of the sprocket by distributing wear more evenly. A similar wear mitigation effect is observed if the number of teeth on the smaller sprocket is a divisor of the total number of pitches on the conveyor chain.

Bore

Conveyor chain sprockets are typically supplied with a bored and keyed configuration, commonly referred to as “Bored to Size.” This feature allows for mounting on a shaft that has a corresponding keyway aligned with that of the conveyor chain sprocket. Bore dimensions generally range from 1 inch to several inches, depending on the shaft size and load capacity. The keyway should conform to standard dimensions (e.g., ANSI B17.1) to ensure proper fit. The use of Taper Lock clamping sets facilitates ease of assembly and disassembly, ensuring precise alignment and secure attachment.

Hub​

The hub diameter is defined as the axial distance across the hub, extending from one side to the other. This dimension can be customized to accommodate specific strength requirements, with typical hub diameters ranging from 1 inch to 6 inches, depending on application specifications. The hub must be sized according to the torque requirements and should allow for keyway and set screw dimensions. Importantly, the hub diameter must not exceed the pitch circle diameter (PCD) minus the conveyor chain’s plate height, which is generally between 0.25 inches and 0.75 inches, depending on chain type. An oversized hub can lead to improper chain engagement, resulting in chain lift from the sprocket’s teeth and decreased power transfer efficiency. Hubs can be designed to extend on one or both sides and may differ in diameter based on the application’s needs. The width of the hub must be sufficient to accommodate a key of adequate length (usually 1.5 to 2 times the diameter of the key) to withstand the torque transmitted by the shaft, thereby maintaining the stability of the sprocket during operation.

Pitch Circle Diameter (PCD)

The pitch circle diameter is defined as the diameter of the circle that corresponds to the centerline of the chain pins as the conveyor sprocket rotates. This measurement is critical for ensuring proper meshing between the sprocket and the chain. The PCD is typically calculated based on the chain’s pitch and the number of teeth, using the formula: PCD=Pitch x Number of Teeth
Where the pitch is usually specified in inches (e.g., 1 inch, 1.5 inches).