So, I'll start by saying that I've done some searching and the I've found these threads that seem relevant:
https://forum.solidworks.com/message/326218
https://forum.solidworks.com/message/325455
http://www.javelin-tech.com/blog/2010/06/one-method-of-modeling-a-chain-in-solidworks/
https://forum.solidworks.com/message/288060#288060
https://forum.solidworks.com/message/69777#69777
https://forum.solidworks.com/message/219331#219331
Among many many others. And I just can not get this to work the way I want.
The point of the chain model is for visual effect in the model, weight calculations, and to get BOM quantities of the chain links. I don't need to animate the chain after creation so even a static assembly of the chain is fine by me.
A lot of the solutions I have found work great...... for shorter chains. I'm often modeling chains for bulk material handeling, so the complete chain loop can be in excess of 250ft. (Not to mention that 250ft of chain takes an entire lifetime to mate together....)
My initial thought before searching at all was to create a spline and then put two points on the chain link, one at each end in the middle of the rivet. Then mate these points to the sketch, and mate the rivets coincidence. Use th "Copy with amtes" feature and just go link by link. This however is VERY time consuming and resource heavy (See 8core, 24 gigs ram, and still crashes.)
The best method I have found still produces the result in the picture I've attached.
Basically all I need is a way to pattern the chain link so that they follow the curve but are still actually connected at the rivets.
I've attached a sample of what I am often trying to accomplish.
Any help/suggestion is appreciated. Ask the obvious questions if you need to, often it's something small that is getting over looked.
Thanks.