Most conveyor systems monitor chain wear, but very few monitor whether both conveyor chains are wearing together. That distinction is more important than many facilities realize.
In overhead conveyor systems, two chains must remain synchronized to keep flight bars square and loads traveling correctly. Even if both chains are still within acceptable wear limits, they can stretch at different rates over time. The conveyor may continue operating normally while a much larger mechanical issue quietly develops.
This is where conveyor deviation monitoring becomes an essential part of a predictive maintenance strategy.
Deviation Monitoring continuously measures whether paired conveyor chains remain synchronized as they move through the system. The process is simple but highly effective.
Two photo-reflective sensors are mounted parallel to one another on opposite sides of the conveyor. As each flight bar passes the sensors, the system measures the exact moment each sensor is activated. When the flight bar is perfectly square, both sensors trigger simultaneously.
If one sensor activates before the other, the system immediately detects that one conveyor chain is leading or lagging behind the other. Even small timing differences can indicate developing mechanical issues long before they become visible during routine inspections.
Instead of waiting for a problem to become obvious, flight bar monitoring identifies the earliest signs of misalignment so corrective action can be taken before production is affected.
Several common conditions can cause paired conveyor chains to move out of synchronization over time, including:
These issues often develop gradually, making them difficult to identify without continuous conveyor alignment monitoring.
A small amount of chain deviation may not seem significant initially, but the effects compound as the conveyor continues operating.
When deviation goes unnoticed:
By the time these problems become visible, repairs are often much more expensive than simply correcting the original chain misalignment.
The earlier deviation is detected, the easier - and more cost-effective - it is to correct.
Many conveyor monitoring systems simply indicate that chain wear has occurred. Mighty Lube's conveyor wear monitoring system provides much deeper insight. Rather than only reporting that a chain is wearing, the system tells you:
A positive deviation reading indicates the secondary chain is leading the primary chain. A negative deviation reading indicates the secondary chain is lagging behind the primary chain. This detailed information allows maintenance teams to make precise adjustments before excessive stress is placed on the conveyor system.
Deviation Monitoring and conveyor chain wear monitoring work best together. A traditional conveyor chain wear monitor answers one important question: How much has each chain stretched?
Deviation Monitoring answers another equally important question: Are both chains still operating together?
When these technologies are combined, maintenance teams gain a much more complete picture of conveyor health. Instead of reacting to failures, they can identify developing problems earlier, schedule maintenance more effectively, and reduce unexpected downtime through conveyor predictive maintenance.
Adding Deviation Monitoring is straightforward for facilities already using a Mighty Lube Chain Wear Monitoring system. The system installs by welding or bolting sensor brackets onto the existing conveyor rail. Two photo-reflective sensors are then positioned to monitor the same flight bar from opposite sides of the conveyor.
Because Deviation Monitoring integrates with an existing Mighty Lube Chain Wear Monitor and controller, facilities can expand their monitoring capabilities without replacing their current system. The result is a fast installation that provides continuous monitoring of conveyor chain synchronization.
Not every conveyor requires Deviation Monitoring, but when paired conveyor synchronization is critical, it can provide valuable insight that traditional chain wear monitoring alone cannot.
Our engineers can evaluate your conveyor system and determine whether Flight Bar / Deviation Monitoring is the right solution for your operation.
Request your Free Conveyor Assessment today and take the next step toward smarter, predictive conveyor maintenance.