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Solution Case Study: Reducing Conveyor Chain Running Resistance for Heavy Loads to Improve Wear Life

Tsubakimoto Philippines Corporation | Conveyor Chain Solutions for the Automotive Industry

The Challenge: Heavier EVs Are Pushing Conveyor Chains to Their Limits

The shift toward electric vehicles (EVs) is reshaping automotive production lines -- and not just in the assembly process itself. As part of this shift, vehicle transport methods are also changing.

Traditionally, vehicles were transported using single-tire conveyor systems. However, to prevent back electromotive force caused by rotational differences between the left and right axles, many EV production lines have moved to double-tire transport.

At the same time, EVs are simply heavier than conventional vehicles -- largely due to battery weight. This combination of heavier vehicles and dual-tire transport has created a new set of operational challenges:

• Increased running resistance on conveyor chains
• Higher load on drive motors, raising energy consumption
• More frequent maintenance, as chains wear out faster under the added strain

For automotive manufacturers, these issues translate directly into higher operating costs and more frequent line interruptions for chain replacement.

The Solution: Bearing Roller Conveyor Chain

To address this, Tsubakimoto's Bearing Roller Conveyor Chain (Large Size Conveyor Chain, Standard Specifications) was adopted to reduce running resistance and extend chain service life under heavier EV transport loads.

What Makes It Different

Unlike standard conveyor chains, the Bearing Roller Conveyor Chain places a cylindrical bearing between the roller and bushing, fundamentally changing how the chain handles friction and load.

Key Performance Advantages

• Approximately 5x longer wear life compared to general-purpose chains (DT Series)
• Roughly one-third the motor power required to drive the system
• Chain size reduced by up to two sizes, while maintaining the same dimensions as the R and F rollers of standard conveyor chains -- making it a practical, drop-in upgrade

The Results

By adopting the Bearing Roller Conveyor Chain, automotive manufacturers have achieved:

• Significantly reduced chain running resistance, even under heavier EV loads
• Improved wear life, cutting down on the frequency of chain replacement
• Lower maintenance costs, thanks to less frequent servicing
• Reduced motor load, resulting in measurable energy savings

Why It Matters for Automotive Manufacturers

As EV production volumes grow, the added weight and transport demands of these vehicles will only continue to strain conventional conveyor systems. Choosing a chain engineered specifically to handle higher loads with lower resistance isn't just a maintenance decision -- it's a long-term investment in production efficiency, uptime, and energy cost savings.

Looking to reduce running resistance and maintenance costs on your conveyor lines? Tsubakimoto Philippines Corporation can help you evaluate the right conveyor chain solution for heavier loads and demanding production environments.

📩 Contact us for inquiries | Learn more about the Bearing Roller Conveyor Chain