12 common bucket elevator troubleshooting | m&c
As a kind of conveying equipment with simple structure, low maintenance cost and high conveying efficiency, bucket elevator is widely used in food, medical, chemical and mining industries, and plays an increasingly important role.
In the actual conveying operation, the efficiency of bucket elevator is affected by the problems of slipping, deviation, tearing, returning, low production and abnormal noise. In this article, we will tell 12 types of troubles and solutions of bucket elevator, to help you produce efficiently!
Reduce the amount of material feeding, and strive to feed evenly, if after reducing the amount of feeding, still can not improve skidding, it may be that too much material is accumulated in the machine or the hopper is stuck by foreign bodies.
1. When lifting different materials, the speed of bucket is different: when lifting dry powder and granule, the speed is about 1-2 m/s; when lifting bulk material, the speed is 0.4-0.6 m/s; when lifting wet powder and granule, the speed is 0.6~0.8m/s.
If the bucket runs too fast, the material will be unloaded ahead of time, resulting in material return. According to the lifting material, the speed of the bucket should be reduced appropriately to avoid material return.
The hopper is the bearing component of the hoist, which has higher requirements for its materials, so the materials with good strength should be selected as far as possible during installation. The general hopper is made of ordinary steel plate or galvanized sheet welded or stamped.
The solution is to increase the air outlet, that is, to set up the air outlet above the discharge pipe of the elevator head, and the outlet pipe leads directly to the atmosphere to reduce the dust concentration in the head so that it can not produce powder explosion.
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4b braime: bucket elevator inspection | bulk-blog
Leeds, United Kingdom Periodic inspections of bucket elevators should be an essential part of any maintenance program. Often it is helpful to conduct these with a trusted vendor who can provide insight into solutions that go beyond just part replacement. The following are examples of common issues found during bucket elevator inspection programs conducted by 4B Components USA. This paper will provide suggestions on what to look for and explain the consequences of each issue.
The rubber surface on this head pulleys slide lagging has worn away and also a section of the lagging has come loose and is in danger of scraping the casing which can create heat and sparks. In addition, the reduced contact between the pulley surface and the belt can cause the belt to slip under load which will also lead to heat. Either of these heat sources could ignite a dust cloud inside the elevator, resulting in an explosion. Finally, if a perforation is worn into the casing dust can escape, and an extensive hot work repair will be required.
To help with early indication of these types of issues the installation of a speed switch on the tail shaft can sound an alarm and provide automatic shutdown before a dangerous belt split condition persists. Also a correctly positioned misalignment switch can detect a misaligned belt, a misaligned pulley or a piece of lagging that has come loose. These sensors can both alarm or shut down the bucket elevator so that corrective repairs can take place.
No matter the precautions taken, tramp material such as rocks, metal wrenches and wood boards can find their way into bucket elevators. The impact of these foreign objects in the product stream takes a toll and can result in broken buckets. Impacts can also knock buckets loose from the belt, diminishing throughput and could actually cause a plug condition. Screens and magnets located at the inlet can help capture tramp material before it enters the elevator. And plug sensors can help to detect a blocked chute. Also, heavier duty elevator buckets with stronger front lips can withstand more impact than lighter duty.
Aside from broken buckets, prematurely worn buckets can diminish throughput and make discharge inefficient. Another consequence could be early discharge resulting in material falling back down the upside of the elevator leg also known as back-legging. Back-legging just adds to the problem of premature wear because additional material ends up in the boot and the buckets must dig through it, wearing them further. Causes of this type could include an under tensioned belt, improper belt speed, excessive digging or material buildup in the boot, or the wrong style of elevator bucket being installed.
If the material being elevated is too abrasive for the bucket resin being used, employing digger buckets or changing to nylon or polyurethane buckets may help. 4B Components engineering group can assist with these issues along with any corrections to the elevator leg design, belt speed and bucket spacing.
The head sprocket on this continuous discharge chain bucket elevator came loose from the shaft because the set screw in the keyway failed. The sprocket wandered and the buckets eventually scraped the casing. Here again is metal-on-metal friction. Aside from wearing the buckets prematurely, this friction is a heat source that could lead to a dust explosion.
The installation of an extended range proximity switch on each side of the leg casing can sound an alarm when the chain moves over and can automatically shut down the elevator if the condition persists.
In a similar continuous chain bucket elevator, the chain barrels are starting to flatten as can be seen circled in the image to the right. This indicates possible chain stretch and / or improper meshing with the sprockets. The chain is wearing prematurely, or stretching, and impeding the efficient function of the entire system.
Periodically inspect the chain barrels and chain for excessive wear, cuts, grooves, or flat spots. Chain barrel wear results in hooked sprocket teeth which accelerates chain wear so it is important to also inspect the sprockets.
The nuts and lock washers that secure elevator bolt fastening systems can come loose. In attention during installation and the constant vibrations of the elevator can work these items loose. This is the reason equipment manufacturers recommend the regular tightening of elevator bolts throughout the life of the bucket elevator. No one wants an elevator bucket to become detached and cause damage.
One solution to this problem is the use of fanged style elevator bolts in conjunction with a nylon insert lock nut (nylock). The fangs bite into the belt cover and prevent the bolt from rotating as a nylock nut is applied. Once in place, it is less likely that the nylock nut will back off due to system vibration. Another solution is the installation of an EASIFIT Elevator bolt. These specialty bolts incorporate a hex at the end of the bolt which locates into a special tool in order to stop the bolt from turning when a Nylock nut is installed.
In this article we have shared six common problems identified during 4B bucket elevator inspections. Many other issues can arise and our team of bucket elevator specialists is qualified to inspect and provide solutions to help bring your bucket elevator back to its optimum performance. Contact us to book your bucket elevator inspection.
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Bethlehem (PA), United States SMART ELBOWDeflection Elbow from HammerTekends formation of streamers, angel hair and snake skins by eliminating impact and frictional heat caused by conventional elbows conveying pelletized resins and compounds when pellets skid against the outside radius of the elbows creating friction and heat, melting pellet surfaces, forming streamers and causing downstream quality problems.
bucket elevator drives replacement & repair - transcyko
Bucket Elevator Drives are designed for the vertical transport of large quantities of materials. The bucket containers are attached to a continuous conveyor belt which passes around a drum at the base of the elevator. The buckets collect their load at the base of the system, are carried up to the top and then release their material as they are rotated at the top of the drive system.
These drive systems are often required to carry enormous loads through vertical elevations of 100-200m or more and they must transport these loads without creating large quantities of dust in the process.
Bucket elevator systems are used widely in Heavy industry manufacturing plants such as steel production to efficiently transport bulk material vertically through the production process. Bucket elevator bevel helical gear units are one of the most widely used applications for our Transcyko TSG gearbox range. These high efficiency drive units are in use now across a range of industries that rely on them for material transport:
The gearboxes for bucket elevator systems must be soft starting because of the high starting power, this is achieved by fluid couplings in the drive chain. Our Transcyko TSG bevel helical gear units are the most common choice for this application.
Legacy industrial gearboxes and equipment may appear at first to be cheaper to repair, but as these systems become older and repair costs increase, replacement with newer technology which is more durable and requires less maintenance is often cheaper in the long run. Replacement also provides additional efficiency and reliability benefits for production.
Changes to any major production components can be very costly for operations. Minimizing disruption, managing costs and ensuring ongoing maintenance are vital for efficient upgrades and retrofitting to deliver real value to the business. Transcyko large industrial gearboxes can be retrofitted to suit your existing space and location configurations.
Other factors such as parts availability, technical service quality, and flexibility may make a move away from an older traditional brand to a more responsive bucket elevator drive partner a more effective solution for your business.
Transcyko Drop in bucket elevator gearbox solutions allow for rapid replacement and upgrade to newer, more efficient technologies with minimal disruption to production operations. Our bucket elevator drive solutions will replace your legacy Sumitomo or other brand gearboxes with newer, easier to maintain designs, backed up by Transcykos renowned gearbox durability, advanced designs, and excellent service.
Transcyko Heavy Duty Industrial drive units carry out the most difficult tasks with maximum reliability. We utilize a modified crowning design to decrease noise, decrease vibration and counter the effects of offset loads. Our gearboxes also feature spherical roller bearings which achieve low friction coefficients with a heavy load bearing capacity.
All of our TSG series gearboxes deliver unmatched reliability in heavy industry operations, with high torque and load bearing capacity as well as low noise and increased thermal performance capabilities.
All of our heavy-duty gearboxes are rigorously inspected to mee the most demanding of customer applications. Our bucket elevator drives deliver maximum performance and reliability as we understand they are a vital component in your production drive train:
bucket elevators: 5 factors to consider for trouble-free feeding and o
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An aspect often overlooked with continuous bucket elevators is the need to consider how material is fed into the unit. As an equipment type, bucket elevators require a controlled infeed of material to operate effectively. Failing to consider how material will be presented to the conveyor can result in lost throughput, product degradation, and equipment damage and downtime.
Bucket elevators can receive material from a variety of upstream process equipment, including mixers, blenders, dryers, pastillators, etc. Irrespective of the equipment type, it is critical to evaluate how the flow of material will be regulated as it enters the elevator infeed. To perform effectively, bucket elevators require a uniform and consistent rate of feed.
In some installations, the need for a regulated flow of material into the elevator is overlooked entirely. For example, we have seen installations where a bucket elevator was being fed directly from a bulk bag (FIBC) discharger without the use of any control device to regulate the flow of incoming material. Feeding an elevator with an unregulated flow of material can result in the following:
To avoid these problems, it is necessary to use an appropriate control or metering device, such as a vibratory or rotary valve feeder, to ensure a regulated flow of material into the elevator. The choice of which type of control device to use depends largely upon the application which the elevator is servicing.
Vibratory feeders use vibration to feed material into the bucket elevator. The amplitude and frequency of vibration, together with the feeders angle of deflection, serve to move a regulated amount of material into the elevator.
Vibratory feeders work well for many material types, especially those that are characterized as fragile or difficult-to-handle. Unlike rotary valve feeders, the design of vibratory feeders allows for a controlled flow rate without any degradation of the material moving through the feeder. Given their ability to control the flow rate with no material degradation, vibratory feeders are a preferred choice in high-care applications where product degradation must be avoided.
A second advantage of vibratory feeders is their consistent feed rates. Due to their design, vibratory feeders avoid the pulsed feeding of material that can result from using a rotary valve feeder. Vibratory feeders are available in fully enclosed tray designs for dust containment or to protect the product from external contamination.
Rotary valve feeders consist of a housing barrel containing evenly-spaced rotating vanes which contact incoming material and move it through the feeder. In applications which use a bucket elevator, a rotary valve feeder can be used as a volumetric feeder to discharge bulk solid material from a hopper or bin directly into the elevator infeed.
As with vibratory feeders, rotary valve feeders offer a fully enclosed feeding solution. This reduces the risk of material cross-contamination that can occur with release of dust into the ambient environment. Rotary valves are also used as an air-lock, suitable for purged systems or used as an isolation device when handling potentially explosive materials.
Given the design of rotary valve feeders, where the rotating vanes of the feeder contact material and move it forward, there is an increased risk of product degradation when fragile materials are being transferred. Thus, rotary valve feeders are often best used in applications involving non-fragile materials. In addition, while rotary valve feeders can achieve consistent feed rates, the rotating vane design can result in a pulsed flow as the evenly-spaced vanes move material through the feeder into the conveyor.
When using a rotary valve feeder, it is preferred to orient the feeders rotational axis to be at 90 degrees to the direction of travel of the buckets. This will ensure an even distribution of material within each bucket.
For continuous bucket elevators, it is preferred to feed material in line to the elevator infeed as opposed to, for example, feeding at right angles to the elevator infeed. Feeding material inline to the elevator infeed permits a more even distribution of material across the width of the buckets. In contrast, feeding the elevator perpendicularly can result in uneven material distribution within the buckets, as well as causing increased bucket wear that results from the more concentrated impact of material. The latter point is a particularly important consideration when moving abrasive materials or heavy products through the elevator. This can be resolved by incorporating a bias cut to either the transition chute, or vibratory feeder tray.
Minimizing the height from which material is dropped into the elevator reduces product dusting and allows for a gentler transfer of material. Ensuring a gentle transfer minimizes particle attrition and is important when handling fragile or friable materials that could degrade when dropped into elevator from too high a height. In addition, minimizing the material drop height reduces impact wear on the buckets, reducing the need for maintenance interventions and replacement parts.
To ensure that no load is present at start-up, the elevator should be started and allowed to ramp up to the desired operating speed before being fed with material. This can be accomplished by setting an appropriate time delay on the control device used to regulate the flow of material into the elevator infeed. The time delay ensures that no material enters the elevator until the operating speed is reached, avoiding any potential damage to the conveyor.
Transition chutes contain and direct material as it transfers from an upstream process into the elevator infeed. Material containment is particularly important when handling hazardous or toxic materials, which usually require fully enclosed connections. These sealed connections would be made either using a direct flanged or a flexible type. Transition chutes should be designed with a geometry and size that allows for a controlled and even flow of material through the chute and into the elevator.
When buying and installing a continuous bucket elevator, be sure to discuss with the equipment manufacturer all aspects of how the unit will be fed. Addressing the factors described above will ensure that the elevator is uniformly fed with material and help avoid performance problems that can result from improper feeding.
James Bransfield is the engineering team leader for UniTrak Corporation Ltd. UniTrak manufactures the TipTrak line of continuous bucket elevators. For more information, contact Bransfield at [emailprotected] or visit www.unitrak.com.