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Belt Bucket Elevator Design
Belt Bucket Elevator Design
Belt Bucket Elevator Design
From www.feedforward.com.au
Code
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Article Title
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2.0
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9.0
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Sharp edges
Free
Less than 2%
Firm
Consistent
Ambient
30 degrees
Corrosive if damp
Dry and airy
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v 2 = g r cos
cos = 1 at top dead centre.
Therefore r =
v2
and diameter (d ) = 2 r
g
HOR. DIST.
(mm)
VERT. DIST
(mm)
0.1
120
50
0.2
240
195
0.3
360
440
0.4
480
780
0.5
600
1220
From the table it is noted that after 0.2 seconds of flight the
product has traveled 240 mm horizontally from top dead
centre and 195 mm vertically. The pulley radius is 150
mm which means the product is clear of the pulley by 90
mm. But it is not yet clear of the 270 mm radius circle
scribed by the lip of the bucket (allowing for belt
thickness).
V (m / s)
RPM =
60
2 r ( m)
Usually a 4-pole motor at 1450 RPM with a reduction
gearbox of suitable ratio is selected to drive the head
pulley. The gearbox can be a direct drive or shaft-mounted
unit depending on the available space and access.
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90 Wb
Ps
90 1700kg / m 3 0.0005m 3
= 109 N
0 .7 m
2 38 176 0.2
= 147W
60 1000 0.98
As a check on the calculation To lift 5,000 kg/hr to a height of 5.5 m allowing for 50%
efficiency overall.
5000 9.81 5.5
= 540kNm
W=
0.5
W 540,000
=
= 150W (which is close to the previous
P=
3600
t
answer considering the actual efficiency is unknown).
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T1
= e where e = 2.718 (base of natural logs)
T2
= Coefficient of friction
= arc of contact in radians
1100
1.2
=
= 1.68kN
T1 =
1
1
1 0.25
1
e
e
T2 = 0.77 kN
S e = K b K cb M 2 + K t K ct T 2 = Fs Z p
where M = largest bending moment Nm
T = shaft torque
Kb = shock factor bending
Kt = shock factor torsion
Kcb = stress concentration factor bending
Kct = stress concentration factor torsion
Fs = allowable shear stress (MPa)
Zp = polar section modulus = d3/16 for a solid bar
The maximum allowable shear stress is half the maximum
principle stress. In addition a factor of safety of 2 for
shock loading and stress raisers is included.
For rotating shafts under minor shock loads Kb varies from
1.5 to 2.0 and Kt varies form 1.0 to 1.5. In heavy shock
load conditions Kb varies from 2.0 to 3.0 and Kt varies
form 1.5 to 3.0. Stress concentration factors can be found
from stress concentration graphs for the form of stress
raiser involved.
S e = K b K cb M 2 + K t K ct T 2
= 1.5 129.5 2 + 1.5 312 = 163 Nm = 163,000 Nmm
No allowance was made for stress concentration since the
shaft will be mounted to the pulley by taper locks, which
do not require the shaft to be machined. If the shaft is
stepped it will be necessary to factor in stress concentration
effects.
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Se =
Fs
F
d 3
Zp = s
2+2
2 + 2 16
d (mm) =
16 S e
Fs
4
16 S e Fs
Fs
F d3
Zp = s
and d = 3
4
4
16
16 163,000
= 25mm
225
4
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constructing the pulley drum of 20 mm or 25 mm round bars of length wider than the belt. The bars are spaced around the
end plates with gaps for product to fall through. Size the spacing between ribs with sufficient clearance for small product
to fall through. Larger product will not fit through the gaps.
provide a twin opposed-cone hub with the cones base starting at the center and tapering to the shaft at the ends of the
pulley. 20 mm or 25 mm round bars are welded to the outer rim of the cones and gussetted back to the cone wall for
stiffness.
The pulley can be mounted to the shaft using taper locks fitted to suitably sized hub, interference press fits, retainers screwed
and doweled to the shaft, hubs screwed and doweled to the shaft or key way in the hub and shaft.
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Dusty surroundings are one of the most difficult environments for bearings. In equipment handling powders or in processes
generating dust the protection of bearings against contamination by fine particles requires special consideration.
BEARING HOUSINGS
Bearings are contained within a housing from which a shaft extends. The shaft entry into the housing offers opportunity for
dust (and moisture) to enter the bearing. The shaft seal performs sealing of the gap between the housing and shaft. Choice of
the appropriate shaft seal and seal configurations to protect against dust ingress is critical.
provide two or more seals in parallel. Bearing housings can usually be purchased with combination seals as standard.
ii. retain the housing shaft seals but change from a greased bearing in the housing to one which is sealed and greased for life.
If contamination were to get past the shaft seals, the bearings internal seals would protect it.
iii. stand the bearing off the equipment to create a gap between the end of the equipment and the bearing housing while sealing
the shaft at the equipment.
iv. put in a felt seal wipe between the housing and the wall of the equipment to rub the shaft clean. Install of a mechanical
seal in very harsh environments.
v.
install a grease barrier chamber sandwiched between two seals. This barrier is separate to the bearing housing and acts as
the primary seal for the bearing. Grease pumped into the chamber will flush out past the seals.
vi. replace the grease barrier chamber instead with an air pressurised chamber.
vii. shield the bearing housing from dust with use of a specially fabricated rubber shroud encapsulating the housing and wiping
the shaft or fit a rubber screen with a hole wiping the shaft over the opening emitting the dust.
viii. flush the bearing with grease by pumping excess grease into the housing and allowing the grease to be forced past the shaft
seals or through a purposely drilled 15mm hole in the housing. The hole must be on the opposite side of the bearing to the
grease nipple, at the bottom of the bearing housing when in service and between the bearing and seal.
ix. Mechanical seals can be fitted to the shaft with the stationary seal sitting toward the machine and the rotating seal mounted
back along the shaft. Combinations of other seals and wipers can also be used in conjunction with the mechanical seal.
Mount the auxiliary seals so they see the dust/water first and keep the mechanical seal as the last line of protection.
Some conceptual examples are shown in Figure No. 2.
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ASSEMBLY
The process of assembling a bearing into the housing must be spotlessly clean. If contamination occurs at the time the housing
is assembled no amount of external protection will stop the bearing from premature failure. When assembling bearings into
housings make sure that:
i. your hands have been washed.
ii. the work bench is clear and wiped down clean.
iii. no one creates dust or grinds nearby during assembly.
iv. fresh, clean grease is used to pack the housing.
v. the components are clean and all old grease has been thoroughly removed.
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The drive pulley can be either the top or bottom pulley. With a top pulley drive the motor and gearbox are clear of product
spills and dust fall-out. The belt tension only needs to be sufficient to provide enough friction between belt and pulley to lift
the material. Access platforms to the drive at the top of the elevator is needed for belt tracking and maintenance.
With bottom pulley drive maintenance access is easy but belt tension is doubled to provide the same drive friction. This
increases loading on all the moving components. If the bottom drive pulley becomes coated in product or the belt stretches, the
belt slips. Top pulley drives have less operating problems.
Where the bucket elevator is used for multiple products, quick cleaning access for operators is required. Flanged and bolted
access doors seal well but removal is slow and threads become crusted with dust. Other options on non-hazardous materials are
to use doors like those in the drawings below.
The bottom pulley ought to be a self-cleaning design and not allow product to build up between belt and pulley. One method is
to use round bar to create a grizzly bar design.
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Gluing rubber to the drive pulley will increase the drive friction. Cut the rubber splice at an angle of 45 degrees to the pulley
axis so the splice gradually feeds into the friction area of the pulley.
The belt speed must be sufficient to throw the material clear of the bucket and into the outlet chute. Too slow and the material
slides from the upturned bucket as it comes over the top pulley and falls back to the bottom of the elevator. Too fast and the
material is flung out too soon and hits the top of the elevator before falling back to the bottom. Formulas are available to
determine the right belt speed and throw for the material.
The pulley shaft bearings are best mounted on standoff brackets to the outside of the elevator housing in case the shaft seals
leak. Shaft sealing should be well designed to stop any leaks. The UP-TIME article on Protecting Bearings in Dusty Places
(Code No. 111) can be consulted for some useful shaft sealing ideas.
Feeding the product into the elevator boot is done by allowing material to fall through a chute under gravity or by forced
methods such as a powered feed screw. Both the feed chute angle and its cross section must be large enough to prevent product
hang-up or build-back. A clear passage without obstructions is critical. Similarly the discharge chute angle, size and design
must allow product to flow freely.
Pressurisation commonly occurs inside the elevator housing as the buckets drag air on the downward run from top to bottom.
When the feed rate into the elevator boot is less then the removal rate of the buckets, the flow of air is carried through the filling
section and upward with the filled buckets. Dust is raised inside the elevator and the internal air pressure forces the dust out
through openings and seals. The problem is worst with powdery or dusty products.
If it is important to reduce the amount of dust, the boot should be kept choked without bogging the elevator. Increasing the
feed rate into the boot slightly above the bucket removal rate will cause plugging. With such a feeding arrangement it would be
necessary to also install build-back detection to periodically stop the feed until the boot was cleared. An alternative,
successfully used on powdered products, is to feed the product in from the downward side of the elevator. With this method the
product filling the boot moves through with the bucket and both product and bucket act to plug off the bottom of the boot to the
flow of air.
Quick detection and stoppage of the feed to a bogged bucket elevator is critical. When this is overlooked the belt stops but the
drive continues to run. If undetected the rubber on the drive pulley peels off and the belt is eventually worn through. To detect
bogging, a proximity detector is fitted to confirm the presence of rotation of the non-drive shaft. A stationary shaft would raise
an alarm and stop the elevator and feed system.
Mike Sondalini - Maintenance Engineer
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HAZARDOUS ZONES
The designation (naming) of the zones reflect whether the hazard is a flammable gas or an explosive dust and the likelihood
that a hazard will be present. For a gas/vapour the zones and their definition are listed below.
Zone 0 a volume of space an explosive gas atmosphere is continuously present. An example is the vapour space in a fuel
storage tank.
Zone 1 a volume of space an explosive gas atmosphere occurs periodically in normal operation. An example is while
filling the fuel tank of a car.
Zone 2 a volume of space an explosive gas atmosphere is not normally expected and if it does occur, it will only be
present for a short period of time. An example is a spill from overfilling a car fuel tank.
R3.0
3.0
VENT
BUND WALL
BUND WALL
4.0
4.0
GROUND
1.0
15.0
15.0
ZONE 0
ZONE 1
ZONE 2
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The other explosion principle used in hazardous areas is to select electrical equipment and designs that remove the ignition
source. Table No. 2 lists the explosion techniques available. They must be selectively used as they can only be applied in the
appropriate hazard zone.
Method
Exclusion sealing ignition source
away from gas or dust inside an
enclosure
Symbol
DIP
Ex m
Ex n
Ex o
Ex p
Ex q
Ex d
Ex n
Type of Protection
Dust ingress protection
Encapsulation
Non-sparking (Permanently sealed devices, restricted breathing
enclosures)
Oil-immersion
Pressurised enclosure
Powder or sand filled
Flameproof enclosure
Non-sparking (enclosed-break devices)
Ex i
Ex n
Intrinsically safe
Non-sparking (non-incendive components)
Ex v
Ventilation
Ex e
Ex n
Ex s
Increased safety
Non-sparking (inherently the operating temperatures are low)
Special protection (designed for a purpose)
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UNDER-CURRENT SITUATIONS
When a motor is freewheeling, or it is very lightly loaded, the current required to just turn the motor is only a small portion of the full load
current. If such a situation develops when a motor in operation it is probably because something abnormal has occurred.
A typical low-load situation arises when centrifugal pumps are deadheaded against a closed discharge valve or if a downstream suction valve
is shut and the pump is cavitating because it is starved of liquid. In this case undercurrent protection would detect the low load on the motor
and turn it off. If the pump had a mechanical seal it would be protected from damage before loss of lubricating fluid across the seal faces
destroys the seal.
Another situation where undercurrent protection would be useful is in the detection of unloaded conveyors or bucket elevators. They could
be turned off automatically after a period of time. Anytime the components in a drive train fail, for example the shaft coupling breaks, or a
drive shaft breaks or drive belts come off or snap, the motor load would suddenly drop and the fall in load current could be used to trigger a
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The smaller the dust particle then the easier it is to make airborne and the longer that the particle will remain suspended
once airborne.
The less dense the dust particle then the easier it is to make airborne and the longer that the particle will remain suspended
once airborne.
So, smaller lighter particles are more prone to creating dust, and once airborne are less likely to disperse. Within a dust
collection system this means that they are easier to capture and transport.
Volume and Scatter of Particles
The greater the volume of particles then the more opportunity there is to create dust. The exposed surface area or scatter of the
particles also influences the opportunity to create dust.
A bucket of particles compactly piled will generally require more effort to make airborne than the same volume spread widely
as it presents more particles. The greater the scatter then generally the greater the area affected by dust.
Wind or Air Flow
The volume and velocity of wind can result in both a positive and negative effect on dust.
If dust is being created by other source then wind or airflow will disperse the dust. This may be beneficial if small amounts of
dust are being created, as it will prevent the build up of a high dust concentration. If the amount of dust being created by other
source is high then wind or airflow will spread the dust over a large area. Whilst this may reduce the dust concentration at the
source area it may result in a larger dust problem to both people and environmental emissions.
Wind is the cause of lift off or pick up from stockpiles and the ground. Essentially the stronger the wind the larger the particles
able to be lifted off and the greater the volume of particles lifted off.
Within a plant area tunneling of the wind often occurs where by the velocity of wind increases when it is forced through a
constricted area. This often occurs between buildings.
The stack or chimney effect is also caused by wind. This is the principle behind the natural draft stacks prior to draft fans.
Essentially the wind blows across the top of an exposed opening creating a low pressure point that draws dust and fumes out.
This is generally noticeable from open hoppers or tanks by small eddies of wind disturbed dust.
Wind velocity increases with distance from the ground. Higher points are more susceptible to the effects of wind i.e. buildings,
stockpiles, transfer points.
Air flow is induced by equipment and product movement. Air can be entrained in the product, induced by the boundary layer
effect of movement or captured by equipment movement. When air is drawn into a transfer or a piece of equipment, this air
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either needs to be controlled (direction, velocity, volume) or removed/expelled. Note the difference between air and dust. The
dust can be filtered or removed from the air.
Moisture or Wetting Agents
This describes the use of water as a wetting agent however it also applies to other liquids that are used to control dust such as
oil.
Water can be used to two main ways to control dust as a prevention measure and then as a capture method.
By having a moist bulk product, the particles adhere together and are less likely to disperse and scatter. The particles adhere to
the water and put simply, they make the particle larger. This principle is often applied to stockpiles to prevent lift off or pick
up.
If particles become airborne then water sprays can be used to capture the particles by having the dust particle adhere to the
water droplet. This principle is often applied but as particle sizes become smaller then it becomes less effective.
Vehicles
Whilst vehicles are generally not responsible for being the initial creator of dust they often result in being a significant dust
source. When a vehicle travels over particles on a roadway several things may occur.
The particles may be pulverised resulting in smaller particles that are more easily able to become airborne.
The particles are picked up by tyres and scattered over a larger area and may become airborne by lifting into the air.
The particles may become airborne from the airflow induced by the vehicle movement.
The amount of airflow is directly related to the speed of the vehicle. The degree of scatter and airborne particles are inversely
related with moisture content. The greater the moisture the greater amount of pick up by tyres and the less airborne dust is
produced.
Build up of particles on vehicles and machinery such as front-end loaders (FEL) and bobcats result in a significant amount
particle scatter and particles becoming airborne through induced wind lift off.
Evans Rabbit vs Sheep Theory of Dust Control
Often people try the rabbit theory on dust. Firstly they say it is just a couple of rabbits and nothing to worry about and certainly
not worth spending money on. As the problems gets larger very quickly the method used to control the problem is shoot all
rabbits on sight. This ends up being very time consuming, labour intensive and ends up costing lots of money in bullets. This
is often occurs in dust collection by putting lots of dust take-offs on dust collectors.
There ends up being too many take-offs that dont work efficiently because the dust collector has a limited useful capacity, and
then there is a call for a bigger dust collector. More dust take-offs and a bigger dust collector means collecting more dust,
which must mean the dust problems, are being fixed. Wrong! The dust problem is what is on the outside of the dust collector.
Once you collect more dust you then have the problem of what to do with it. Once you have more dust collectors the capital
cost goes up, the maintenance cost goes up and the operating cost goes up. You need to minimise dust collection points to
those that are most effective.
The sheep theory to dust control is containment, control and collection. Like sheep, dust is dumb and tends to have a mind of
its own wandering around aimlessly following each other. Sheep are kept in fenced paddocks and herded all together in a
flock to a collection point. This is what to do with dust.
If there is a hole in the fence and sheep are getting out you fix it. If a small flock of sheep runs off bring them back to the main
flock rather than try herding two flocks. Dont try to move them too quickly or they will break up. Have somebody watching
the flock for stray sheep that run off at all times, get a dog. If a sheep falls on the ground pick it up put it in the ute and deliver
with the remainder of the flock.
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Belt conveyors are used to transport anything from matches to bulk material such as iron ore and quarried stone. The belt can
be made of natural fibres, rubber, plastic or metal. Regardless of its construction and purpose there are basic requirements to its
successful operation that must be met.
How a Belt Conveyor Works
Figure No 1 is a simple sketch of a belt conveyor. An electric motor and gearbox turn the head drum (or head pulley). The belt
is pulled tight to produce friction between it and the head drum. The friction overcomes the load and drag forces and the belt
moves around the circuit from the head pulley to the tail pulley and back to the head pulley.
Belt wear and gouging from product impact at loading zones, from belt drag across solid surfaces, from scrapper rubbing,
from the belt touching caught product, from product hardening on scrappers, from drive pulleys slipping during start-up or
during a belt jam, from product build-up on trough and return rollers.
Frayed belt at edges due to rubbing against structures, due to rubbing against product caught in structures, from rubbing
against seized rollers.
Belt Stretch from excessive belt tensioning, from belt aging, from high product impact, from overloading with product,
from running the belt beyond belt design speed, from too much stop-start inertia forces.
Belt distortion due to out-of-square joining, due to a join being too thick, due to ripping and buckling within the belt
material as internal fibres tear because of overloads, due to loading one side of the belt.
Bad tracking due to head pulley misalignment, due to no head pulley crowning, due to trough and return roller
misalignment, due to roller seizure producing more drag. Also can be due to the last upper roller being too close to the
head pulley and lifting the belt so it makes first contact far around on the head pulley circumference.
Gearbox/drive mounting deflection causing shaft misalignment by support frame and load carrying members being
undersized and insufficiently braced for the operating forces and inertia force changes.
Cut belts from impact of product, from dragging across jammed sharp objects, from tearing due to sudden overloads, from
bolts and foreign metal objects gouging.
Scrapper failure from product build-up on the scrapping edge, from jammed scrapper parts, from wrong set-up.
Slipping belt due to product jam, due to loss of belt tension, due to dust/dirt/moisture under head drum.
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Insure joins are square to the running direction of the belt so that the belt runs as straight and true as possible.
Drum Crowning
Belt tracking is greatly improved when one of the drums is crowned. The drive pulley is the one usually crowned though the
bottom drum can also be used. Only one of the drums is crowned and not both. Crowning allows the natural elasticity of the
belt to act like a spring and pull the belt back down the rise of the crown if it starts to wander to one side. The height of the
crown is 1.5% to 2% of the pulley length.
Tracking Belts in Place
Once the belt is installed and pulled tight, the distance between drum shafts is measured on both sides and positioned the same
distance apart. The belt is run unloaded and if it wanders the tail pulley is adjusted and made tighter on the side the belt moves
toward. The basic rule is that the belt moves toward the slack side and away from the tight side (this is also why crowning one
pulley works). Another way to look at it is that the belt goes from the high-energy side (tight) to the low-energy side (loose).
Once the unloaded belt is running true product is then introduced onto it. If the belt wanders under load the tail pulley is further
adjusted as was done when set-up unloaded.
Only tension the belt enough to insure it does not slip under full load. Over-tensioning the belt rips the internal fibers and the
belt stretches and creeps continuously.
All snub rollers, carrying rollers and return rollers must be square to the centerline of the belt and parallel to each other. Check
this by measuring diagonals, which should be equal.
Some times the belt can take on a banana shape or crescent camber along its length. Usually this is a sign of uneven internal
fibre lengths. In this case the belt wanders from side to side during a rotation and little can be done to control it except to get it
running as near to center as possible. Depending on the severity of the banana it may even require that one of the drums be
offset from the center-to-center alignment so that the belt stays on the pulleys. If the camber exceeds 1% of the belt length
replace it.
It can also be useful to install digging buckets every tenth bucket. These buckets are slightly oversize in length and depth to
the rest of the buckets and act as a scrapper to clear away any product build-up on the sides of the structure. Make them of
metal or a harder material than the regular buckets.
Mike Sondalini Equipment Longevity Engineer
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