Skip to content
What Makes a Roller Chain “Premium”?
|
|
Time to read 8 min
What Makes a Roller Chain “Premium”?
When it comes to something so simple, like a roller chain, it’s hard to imagine just how complex it can really be. Inadvertently, the terms “premium”, "super premium", or “tier 1” have become more frequent in our industry over the years, with everyone claiming to have the best product at the most affordable price. Here at USA Roller Chain, we take an in-depth look at the different quality levels of roller chains and what qualifies a chain as a premium product. We’ll also discuss in this article when it’s even necessary to run a premium roller chain, along with some application examples.
“Premium” VS. Our Premium Chain
With the terms “premium” and “super-premium” being used loosely, we decided to create an article based on our industry experience, knowledge, and application expertise to demonstrate our criteria for what qualifies a chain to be considered premium and how we classify quality levels for our clients. As a leading authority in Power Transmission, we feel it is our obligation to educate people, even if they are not using USA Roller Chain products. The example shown here is a typical chain being marketed as “premium.” Now, compared to some chains, it has some superior attributes, but it does not meet the criteria of the team here at USA Roller Chain for being considered a “premium” roller chain. We would not supply our clients with this example chain under the premium classification because of some missing critical features.
Note: This comparison was done with ANSI 60 roller chain.
General Features of Premium Roller Chain
Solid Bushings & Solid Rollers
One of the core components of a roller chain is the round parts (bushings & rollers). Drastically improving chain wear life and performance of transmitting energy, solid bushings and rollers provide perfectly cylindrical bearing surfaces. Solid round parts require special manufacturing equipment that most factories will not make the initial investment in; however, the improvements in wear life and performance versus a chain with split round parts outweigh these costs in the long run. The issue with a split bushing or a split roller is when a chain experiences shock load or is used for some time, the split components will begin to deform, causing excessive internal wear and friction.
Through Hardened Pins
At the center of every roller chain is a pin! The pins are the component that determines the allowable load a roller chain can handle, also referred to as the working load or tensile strength. Premium roller chains will have through-hardened pins that are made from high-grade materials such as SAE 15B41H, AISI 15B41, or SAE 15B25, which is superior in strength compared to material grades used in other components of the chain. Lower tiers of roller chain use processes such as case hardening or simple heat-treatment, but once the hardened outer layer of the pin has worn through, the chain will wear exponentially. The superior through-hardened pins provide an extended lifespan and increased working load strength. Furthermore, premium roller chains should have a pin hardness rating of at least 42 HRC.
Wide Contour Plates
One of the most distinguishing and noticeable differences between a standard roller chain and a premium one is that premium roller chains feature these special, wide contour side plates. The design enhances a chain’s wear life by reducing elongation over time while increasing its shock load and working load capacity. This unique side plate design dimensionally conforms with ANSI standards and imposes no issues whatsoever with the function of a roller chain.
Superior Pin-to-Plate Contact
When it comes to the contact between the outer surface of a roller chain pin and the inner hole surface of the side plate, it is essential to have as much pin-to-plate contact as possible. Most standard roller chains on the market use a simple one-punch method for making the holes in their side plates. The problem with this method is that it leaves the inner surface of the plates with micro inconsistencies, which means the pin does not fully engage with the plate, potentially causing chain failure, pin rolling, and elongation at a faster rate. However, with premium chains, the plate holes are typically double punched, punched and shaved, double punched, or punched, shaved, and ball drifted. These methods ensure more pin-to-plate contact!
High-Hold Riveting
Perhaps one of the most essential features that a premium roller chain has over cheaper alternatives is superior rivets. This is one of the final steps in manufacturing a roller chain. A premium chain will utilize specialized riveting techniques, such as high-hold dual staking, quad-staking, and spun riveting. Quad staking and spun riveting are the absolute best options, but some tier-one chains still utilize a specific type of dual staking process that meets ample chain riveting needs. Most standard chains are made with a very simple dual stake that doesn’t provide as much plate-holding power, and often has inconsistencies in the rivet throughout the chain that are noticeable. A high-hold rivet type, combined with superior pin-to-plate contact, enhances the chain’s ability to withstand high shock loads and prevent failure in the event of slight misalignment in the system.
Factory Preloading
Preloading a roller chain is the process by which the chain is subjected to a load at a specific percentage interval based on the chain's rated tensile strength. This process not only reduces initial and over time elongation, but it also ensures precise alignment of pins, bushings, and link plates. Pre-loading is a staple for premium roller chains for the extended lifespan and overall performance of the chain.
Additional Premium Roller Chain Processes
Specific heat treatments are applied to rollers, bushings, pins, and sideplates to enhance fatigue resistance and load capacity.
Premium alloy and carbon metalergy materials (AISI 1541, SCM420, SAE1035, etc..) paired with high precision tolerances on all components. If a chain's base material properties are subpar, it doesn't matter what is done in terms of processes. High precision tolerances improve performance and wear life.
Shot peened components for improved fatigue resistance, lifespan, and prevention of cracking. This process creates layers of compressive stress, which significantly improve the shock load capabilities of roller chain components all around!
Where are Premium Roller Chains Made?
Based on our analysis of raw material/ metallurgy, features, and real-world application performance, the majority of premium roller chains originated from India, Japan, the United States, and Germany. That’s not to say that there are no premium chains manufactured in other countries; this was based on our experience within the industry and independent testing done across a wide array of chain brands.
When do you need a premium roller chain?
Not all roller chain applications necessarily need a genuine premium roller chain. There are always a few guidelines we at USA Roller Chain like to follow for recommending when someone should use a premium chain. The table below organizes when someone needs to use a premium roller chain based on the application, individual/ plant manager needs, and serviceability.
| Applications | Individual Needs | Serviceability |
|---|---|---|
|
Outside of specific applications, premium roller chains may be preferred by individual maintenance and plant personnel for their maintenance schedule needs or to reduce downtime due to roller chain failures. | Another critical factor in deciding on a premium chain is the actual serviceability of the application. We recommend considering a premium chain in applications that are difficult to access or in scenarios where the chain is on a critical piece of machinery. We also supply premium roller chains in our Problem Solver series, such as O-ring roller chains or self-lubricating roller chains, which are ideal for applications where lubrication or servicing is difficult or where high amounts of dirt or dust are present. |
Shop Our Premium ANSI Roller Chains
Roller Chain Quality Classes
When classifying the specific quality level of a roller chain, we use three different classes: Premium/Premier, General Duty Plus, and Economy Plus. Each class has its own set of specifications that it must conform to, allowing the team at USA Roller Chain to determine which class the chain falls under for our customers. The examples on the left are a visual representation of each quality level.
The standard industry language used to describe different roller chain classes in terms of quality is as follows:
- Tier 1 - Premium/ Premier
- Tier 2 - General Duty Plus
- Tier 3 - Economy/ Economy Plus
Roller Chain Quality Classification Chart
What Can it Cost Running a Cheap Chain?
When it comes to cost, cheaper isn’t always better, depending on your equipment, as other mechanical components, such as bearings, reducers, electric motors, and sprockets, often operate in conjunction with the roller chain. Utilizing an inexpensive roller chain not only poses a risk of premature wear on parts but can also cause costly downtimes and damage to equipment. When it comes to roller chain, we recommend opting for a premium roller chain when there are expensive corresponding components that rely on the chain’s operation, or when the roller chain powers costly equipment.
Roller Chain Sprocket Wear
With most “cheap” or economy-grade roller chains, the tolerances are much looser than a premium roller chain; these chains are typically not pre-loaded either. The result is a “sloppy” or loose-running chain shortly after installation. The elongation that occurs can be detrimental to a sprocket’s wear life and create a higher degree of friction, which also affects other components in the system.
Bearing Failure
Interestingly, operating a drive with inexpensive or low-quality roller chain has adverse effects on bearings. Because of the looser tolerances on some of these chains, there is an increased level of vibration. This affects the bearings within the electric motor, gear reducer, idler shafts, and idler sprockets by reducing their lifespan.
Machine Failure and Downtime
Perhaps in some applications, the costliest aspect of using a subpar roller chain is the downtime and damage caused when the chain fails. A failed roller chain can cause an entire operation to come to a screeching halt, resulting in lost production, increased labor costs due to team members unable to perform their tasks, and additional maintenance labor required to repair the equipment. Now, roller chains fail for a large number of reasons that may not always be directly tied to the quality of the chain. However, for critical machinery or conveyors, premium roller chain should be considered because it will provide the best possible outcome in terms of lifespan, performance, and failure prevention for the conveying and/or drive chain.
