The author claims copyright over all the material in these notes – 15 March 2001.
CONTENTS OF DESIGN NOTES
1.0 Overview of belt bucket elevators and their use.
Postal: FEED FORWARD PUBLICATIONS, PO Box 578, BENTLEY, West Australia, 6102. 1
E-mail: info@feedforward.com.au. Web: www.feedforward.com.au.
DISCLAIMER: All best endeavors have been made to insure the accuracy of the information in these notes. Because the context in which
the notes are used is unknown we accept no responsibility for the consequences of using the information contained or implies within them.
FEED FORWARD PUBLICATIONS
OVERVIEW OF BELT BUCKET ELEVATORS
PURPOSE OF BUCKET ELEVATORS
Bucket elevators are used to lift bulk materials from one height to another. They are a reliable and well-
proven piece of equipment.
METHOD OF OPERATION
Bucket elevators operate by using an endless belt or chain on which rectangular buckets are mounted. The
belt or chain revolves between a top and bottom pulley and the buckets move with it. At the bottom the
buckets pick up product fed into the elevator boot and at the top the product is discharged as the bucket
turns downward over the head pulley.
Along with each type of elevator, different styles of buckets have been developed which better suit the
elevator or the materials to be handled.
Postal: FEED FORWARD PUBLICATIONS, PO Box 578, BENTLEY, West Australia, 6102. 2
E-mail: info@feedforward.com.au. Web: www.feedforward.com.au.
DISCLAIMER: All best endeavors have been made to insure the accuracy of the information in these notes. Because the context in which
the notes are used is unknown we accept no responsibility for the consequences of using the information contained or implies within them.
FEED FORWARD PUBLICATIONS
The left-hand column provides descriptive text. The right-hand column provides an example.
NECESSARY INFORMATION NECESSARY INFORMATION
Required product parameters. Product parameters.
Service use. Raise crushed product from mill outlet to storage silo.
Material chemical name. Aluminium Sulphate.
Bulk density – mass/volume – kg/m3 1700 kg/m3
Maximum duty – kg/hr or m3/hr 5,000 kg/hr
Maximum lump size - dimensions 3 mm max
average size 2 mm
percentage of lumps in total Nil
Height product is to be raised (meters) and angle of incline 5.5 m including length of discharge chute into 4 m high
if any. Provide enough height at the outlet of the discharge storage silo.
chute so the product is always falling following discharge.
Product characteristics – abrasiveness Sharp edges
flowability – free/cohesive/slug Free
dampness – % moisture Less than 2%
friability – firm/breaks/powders Firm
particle shape – Consistent
length/size/volume Ambient
temperature of product 30 degrees
angle of repose Corrosive if damp
corrosiveness Dry and airy
Operating environment, location and conditions –
corrosive/damp
Service required – continuous/intermittent. Intermittent – up to 12 hours per day 6 days a week
Open or closed boot design. Open boot bottom, elevator will sit on a concrete floor.
SELECT BUCKET SIZE AND SPACING SELECT BUCKET SIZE AND SPACING
The size and number of buckets is determined from the 5,000 kg/hr throughput.
required throughput using an iteration process. Select a bucket 150 mm wide x 100 mm projection with a
volume of 0.78 litre.
Select the bucket from the range in the bucket supplier’s
Using 2/3 of the volume give a capacity of 0.5 litre.
catalogue. Only 2/3 (67%) of the bucket’s design capacity
0.5 lt. is 0.0005 m3 and holds 0.85 kg of product. (0.0005
is used in calculations.
m3 x 1700 kg/m3).
Centrifugal discharge conveys usually have a spacing To move 5000 kg/hr using 150 x 100 buckets requires
between buckets that is 2 to 3 times the bucket projection, 6,000 buckets per hour or 100 buckets per minute.
though the spacing can be greater for free-flowing Select a bucket spacing of 300 mm.
products.
DETERMINE BELT SPEED
DETERMINE BELT SPEED 100 buckets per minute/60 sec per minute = 1.7 bucket/sec.
The bucket spacing times the number of buckets per 1.7 bucket/sec x 0.3 m = 0.5 m/sec. This is too low and
second determines the required belt speed. The speed for will prove to be insufficient for a clearance throw into the
centrifugal bucket elevators is usually in the range of 1 m/s discharge chute. The bucket spacing will need to be
to 2 m/s to insure the product throws into the chute at the increased and the calculation repeated.
head pulley.
CALCULATE HEAD PULLEY DIAMETER
CALCULATE HEAD PULLEY DIAMETER v2 (0.5m) 2
A simplifying assumption is made that the throw r (radius ) = = = 25mm
g 9.8m / sec 2
commences at the top of the head pulley. At this point the
centrifugal force and gravity force are balanced. The head pulley diameter is 50 mm. This size, though
cos b accurately calculated, is not practical. It is far too small.
Centrifugal force = m ⋅ v 2 ⋅ where The buckets cannot deform sufficiently to go around the
r pulley without over-stressing both buckets and belt.
m = mass in kg
v = belt speed in m/s The solution is to increase the bucket spacing or to use
b = angle from top dead centre smaller buckets. This then requires a proportionate speed
r = pulley radius in m increase to maintain the throughput. The greater velocity
Gravity force = m ⋅ g where needs a larger head pulley revolving at the same RPM.
g = gravity constant 9.8 m/sec2. However as we are using the smallest buckets available it
Putting both forces equal to each other - is necessary to increase the bucket spacing.
Postal: FEED FORWARD PUBLICATIONS, PO Box 578, BENTLEY, West Australia, 6102. 3
E-mail: info@feedforward.com.au. Web: www.feedforward.com.au.
DISCLAIMER: All best endeavors have been made to insure the accuracy of the information in these notes. Because the context in which
the notes are used is unknown we accept no responsibility for the consequences of using the information contained or implies within them.
FEED FORWARD PUBLICATIONS
v 2 = g ⋅ r ⋅ cos b The belt velocity using a bucket spacing of 700 mm with
the removal rate of 1.7 bucket/sec x 0.7 m = 1.2 m/sec.
cos b = 1 at top dead centre.
The pulley diameter is now
v2 d = r ⋅ 2 = (1.2 2 ⋅ 9.8) ⋅ 2 = 300mm . The diameter could be
Therefore r = and diameter (d ) = 2 ⋅ r
g made slightly larger if so desired.
The load on the belt results from the weight of product 90 ⋅ 1700kg / m 3 ⋅ 0.0005m 3
lifted plus the dredging drag as the bucket scoops up the The dredging load = = 109 N
0.7 m
product. A duty factor is used to accommodate start-up
loads. Total pulley load = (67 N + 109 N) = 176 N
Belt Load = (total bucket load + dredge load) This load acts at the centre of the buckets, which have a
projection of 100 mm. The radial distance to the bucket
The bucket load is the sum of the loaded buckets on the centers is 150 mm + 50 mm = 200 mm
upward side. The dredging load can be estimated either by
adding an equivalent length (5m for continuous buckets, 2 ⋅ p ⋅ 38 ⋅ 176 ⋅ 0.2
12m for spaced buckets) to the belt or by use of the Power pulley = = 147W
60 ⋅ 1000 ⋅ 0.98
following formula.
As a check on the calculation -
90 ⋅ Wb
Dredge load (N) =
Ps To lift 5,000 kg/hr to a height of 5.5 m allowing for 50%
efficiency overall.
where Wb = weight of material in each bucket (kg) 5000 ⋅ 9.81 ⋅ 5.5
W= = 540kNm
Ps = Bucket spacing on belt (m) 0.5
W 540,000
A quick check on the load can be done using the formulas P= = = 150W (which is close to the previous
t 3600
for work and power. W = F.s (Nm) and P = W/t = F.v (W).
answer considering the actual efficiency is unknown).
Postal: FEED FORWARD PUBLICATIONS, PO Box 578, BENTLEY, West Australia, 6102. 5
E-mail: info@feedforward.com.au. Web: www.feedforward.com.au.
DISCLAIMER: All best endeavors have been made to insure the accuracy of the information in these notes. Because the context in which
the notes are used is unknown we accept no responsibility for the consequences of using the information contained or implies within them.
FEED FORWARD PUBLICATIONS
CONFIRM DRIVE ARRANGEMENT POWER CONFIRM DRIVE ARRANGEMENT POWER
The load on the motor is transferred through the drive from Power at the head pulley is 147 W. Torque at the head
the head pulley. Simple ratio calculations back to the gear pulley sprocket is directly proportional to the inverse of the
motor shaft will allow determination of the torque at the diameters at which the torque acts.
output shaft. This torque is then compared to the allowable
torque to confirm the suitability of the gear motor. In this calculation the gearbox service factor is 2 and chain
drive efficiency is 0.98.
The power through the gearbox must be increased in
147 ⋅ 2
accordance with - Gear motor power = = 300W
- The manufacturer’s service factors requirement for 0.98
intermittent operation and shock loading.
- Drive efficiency. The logical choice is to select a small 0.55 kW or 1.1 kW
4-pole motor. For the calculation use a 1.1 kW motor, as
With the power through the drive train known, the chain this will permit altering sprocket sizes if operating duties
selection can be confirmed by the chain supplier or change in future.
calculations performed using appropriate formula.
DETERMINE PULLEY DRIVE SHAFT SIZE DETERMINE PULLEY DRIVE SHAFT SIZE
The drive shaft size is calculated to handle the stresses The conceptual sketch for the head pulley is shown below.
generated by a bogged or jammed conveyor. Allowance is
made for stress concentrations causing metal fatigue and
service factor corrections are also applied. The diameter of
the shaft is selected so that the stresses are well within the
shaft material’s metallurgical capacity.
By this stage initial dimensioned drawings can be sketched
using the information compiled from the previous
calculations.
Commence by constructing a free-body diagram of the
head pulley located in its bearings with the drive sprocket
mounted at the drive end. The head pulley will be
mounted to the shaft using hubs at each end. This allows
the uniform load produced across the pulley by the belt to
be drawn as point loads on the shaft at the mid point
position of each hub.
The forces are oriented in the vertical, including the drive
The position and orientation of the gearbox drive has not sprocket force. This arrangement produces the highest
yet been determined. It is best to design for the loading loads on the shaft. The gearbox can be oriented in the
arrangement that produces the greatest stresses and size the horizontal. Such an arrangement would not have vertical
shaft accordingly. This permits the gearbox to be located loads at the sprocket. The sprocket load would then be at
in any orientation in future. 90 degrees to the belt tension. This would produce less
The loads on the shaft are its own self-weight, the belt and overall stress in the shaft and a smaller shaft could be used.
bucket weights, the belt tension load (from product weight However in this design the worst-case orientation will be
and friction drive requirements) and the drive sprocket used.
force generated by a bogged or jammed conveyor. The
bearings counter all these forces and keep the shaft in It is necessary to determine the tension in the belt to lift the
place. full buckets and overcome the dredging load.
Power = (T1 - T2 ) ⋅ v (Watt) The power through the head pulley is 1.1 kW.
where T1= tight side tension (N)
T2 = loose side tension (N) P 1100
v = belt speed (m/sec) v 1.2
T1 = = = 1.68kN
1 1
T1 1 - mq 1 - 0.25⋅p
Also = e mq where e = 2.718 (base of natural logs) e e
T2
m = Coefficient of friction T2 = 0.77 kN
q = arc of contact in radians
The coefficient of friction for rubber on steel is 0.25 and
for rubber on rubber 0.35. The arc of contact is 180
degrees for bucket elevators provided the bottom pulley is
the same diameter as the head pulley.
Postal: FEED FORWARD PUBLICATIONS, PO Box 578, BENTLEY, West Australia, 6102. 6
E-mail: info@feedforward.com.au. Web: www.feedforward.com.au.
DISCLAIMER: All best endeavors have been made to insure the accuracy of the information in these notes. Because the context in which
the notes are used is unknown we accept no responsibility for the consequences of using the information contained or implies within them.
FEED FORWARD PUBLICATIONS
Combining the above tension equations allows T1 to be The force at the head pulley drive sprocket is in the
determined. proportionate ratio of drive train sprocket diameters.
P 2 ⋅p ⋅ N ⋅ F ⋅ r P ⋅ 60 ⋅ 1000 ⋅ h
Power (kW ) = and F =
v 60 ⋅ 1000 ⋅ h 2 ⋅p ⋅ N ⋅ r
T1 = Newton
1 1.1 ⋅ 60 ⋅ 1000
1 - mq Fgearbox = = 1.84kN
e 2 ⋅ p ⋅ 114 ⋅ 0.05
1.84 ⋅ 101
The weight of the rubber belt depends on the ply of the Fheadshaft = = 606 N
307
belt, its width and length. Since the belt tension is know
The load on the bearings is the sum of the belt tension and
the belt can be selected. The belt supplier can advise the
the drive force considering their direction of action.
belt to be used. Select a belt specifically for bucket
elevators and not horizontal conveyors. Those used on The pulley and shaft self self-load and the belt material
bucket elevators contain more weaving than those for loads will need to estimated and later checked if suitably
horizontal conveyors. Select the belt with a safety factor accurate.
beyond the calculated loads for long life under intermittent
and shock load conditions. The buckets are 150 mm wide so the belt will be 175 mm
wide inside a 225 mm wide elevator frame. The elevator
height is 5.5 m and the belt length about 12 m. For the
purpose of the example a 4-ply 36-oz belt will be used with
a mass of 0.0018 kg/mm width/metre length/ply.
where M = largest bending moment Nm The highest bending stress is at drive-end head pulley hub.
T = shaft torque At the same time the shaft is undergoing torsional stress
Kb = shock factor bending from the drive. The worst case under torsion would be if
Kt = shock factor torsion the buckets were bogged and the geared motor applied full
Kcb = stress concentration factor bending power of 1.1 kW. This produces a torque T at the pulley
Kct = stress concentration factor torsion shaft of -
Fs = allowable shear stress (MPa) 1000 ⋅ P 1000 ⋅ 1.1
T= = = 31Nm
Zp = polar section modulus = pd3/16 for a solid bar 2 ⋅ p ⋅ RPM 2 ⋅ p ⋅ 38
60 60
The maximum allowable shear stress is half the maximum
principle stress. In addition a factor of safety of 2 for S e = K b ⋅ K cb ⋅ M 2 + K t ⋅ K ct ⋅ T 2
shock loading and stress raisers is included. = 1.5 ⋅ 129.5 2 + 1.5 ⋅ 312 = 163 Nm = 163,000 Nmm
For rotating shafts under minor shock loads Kb varies from No allowance was made for stress concentration since the
1.5 to 2.0 and Kt varies form 1.0 to 1.5. In heavy shock shaft will be mounted to the pulley by taper locks, which
load conditions Kb varies from 2.0 to 3.0 and Kt varies do not require the shaft to be machined. If the shaft is
form 1.5 to 3.0. Stress concentration factors can be found stepped it will be necessary to factor in stress concentration
from stress concentration graphs for the form of stress effects.
raiser involved.
Postal: FEED FORWARD PUBLICATIONS, PO Box 578, BENTLEY, West Australia, 6102. 7
E-mail: info@feedforward.com.au. Web: www.feedforward.com.au.
DISCLAIMER: All best endeavors have been made to insure the accuracy of the information in these notes. Because the context in which
the notes are used is unknown we accept no responsibility for the consequences of using the information contained or implies within them.
FEED FORWARD PUBLICATIONS
Fs F pd 3 Fs F p ⋅d3 16 ⋅ S e Fs
Se = ⋅Zp = s ⋅ Se = ⋅Zp = s ⋅ and d = 3 ⋅
2+2 2 + 2 16 4 4 16 p 4
The take-up moves one pulley further away from the other.
The pulley to be moved can be either the top or bottom
pulley. If it is the top pulley the drive must also permit the
pulley to move.
Postal: FEED FORWARD PUBLICATIONS, PO Box 578, BENTLEY, West Australia, 6102. 10
E-mail: info@feedforward.com.au. Web: www.feedforward.com.au.
DISCLAIMER: All best endeavors have been made to insure the accuracy of the information in these notes. Because the context in which
the notes are used is unknown we accept no responsibility for the consequences of using the information contained or implies within them.
FEED FORWARD PUBLICATIONS
To protect against bogging install a proximity sensor to
detect rotation of the non-drive pulley and stop the motor
and in-feed system when motion is no longer present.
Signal to the operator that a problem exists.
CLEAN-OUT CONSIDERATIONS
At times the elevator boot will need to be accessed for
cleaning, especially if multiple products are put through
the elevator.
Postal: FEED FORWARD PUBLICATIONS, PO Box 578, BENTLEY, West Australia, 6102. 11
E-mail: info@feedforward.com.au. Web: www.feedforward.com.au.
DISCLAIMER: All best endeavors have been made to insure the accuracy of the information in these notes. Because the context in which
the notes are used is unknown we accept no responsibility for the consequences of using the information contained or implies within them.
FEED FORWARD PUBLICATIONS
the motor on a plug and lead so power can be remove
during maintenance access.
Postal: FEED FORWARD PUBLICATIONS, PO Box 578, BENTLEY, West Australia, 6102. 12
E-mail: info@feedforward.com.au. Web: www.feedforward.com.au.
DISCLAIMER: All best endeavors have been made to insure the accuracy of the information in these notes. Because the context in which
the notes are used is unknown we accept no responsibility for the consequences of using the information contained or implies within them.