Methods to Extend the Service Life of Bucket Elevators
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Bucket conveyors (or bucket elevators) are vital for vertical/steep-angle bulk material transport in mining, grain, and construction. Featuring mounted buckets on belts/chains, they efficiently move powders, granules, or lumps. Key strengths: high capacity, space-saving design, and adaptability to abrasive/sticky materials with tailored buckets. To ensure longevity, prioritize regular lubrication, wear-part checks, and dust/humidity protection—critical for minimizing downtime.
Methods to Extend the Service Life of Bucket Elevators
Bucket elevators are significant equipment for the vertical transportation of bulk materials within various industries, including grain, mining, and building materials. Their lifespan directly correlates with production continuity and maintenance costs. The service life of the equipment determines the management process that should be built—appropriate selection, meticulous maintenance, controllable components, and environmental adaptation. Specific measures include the following:
Ⅰ. Precise conveyor selection
Selection errors are the primary source of equipment damage. Generally, conveyors are selected based on the right material properties and appropriate working condition. Very abrasive materials, such as iron ore and quartz sand, should be paired with a thick steel plate welded bucket (thickness not less than 6 mm), high-wear-resistant rubber conveyor belt (shore hardness ≥75), or chain drive type. A buffer device should be selected to minimize the impact on the material. Sticky materials, such as starch and fly ash, require shallow buckets with a PTFE anti-adhesive coating to prevent sticking and blockage. Motor power is calculated by "conveying capacity × lifting height ×1.2 safety factor," thus protecting the motor from burning due to overloading and conserving energy.
Ⅱ. Daily Maintenance Reduces Fault Loss
Daily maintenance inspections should be conducted to check whether the bucket fastening bolts are properly tightened (a torque of 20 N·m is necessary) and whether the tension on the conveyor belt is correct (it should sag no more than 1% of the span). Proper and timely handling of belt deviation and slippage will prevent accelerated wear due to increased friction. Rotating parts, such as the bearings in the transmission and the chain pins, are lubricated with lithium-based grease during weekly maintenance. Their quantity must not exceed 1/3 to 1/2 of the bearing cavity volume so that oil sludge does not block lubrication. After stopping the machine, the remaining material in the casing must be removed, particularly when hot materials, like cement clinker, are conveyed. In such a case, the machine must cool down completely before any cleaning operation to avoid deformation due to uneven thermal expansion and contraction of the components.
Ⅲ. Full-Cycle Management of Wearable Components Extends Equipment Life
The buckets, conveyor belts, and chains are the most easily worn-out parts in the conveyor system. Therefore, advance planning for replacements and stockpiling of spare parts is necessary. Buckets are to be replaced when cracks reach a length of 50 mm or when edge wear reaches 1/3 of the original thickness. A conveyor belt is repairable in service with cold bonding or hot vulcanization processes when surface damage exceeds 0.1 m² or joint crack length exceeds 20 mm. Extremely damaged conveyor belts are removed. Chains are replaced when pin wear exceeds 10% of the original diameter, and rollers are pitted and spalled. Do not replace new and old chains in a single drive, as this will cause uneven distribution of forces.It is recommended to store 30% of spare parts according to the equipment’s wearable component list, and the storage environment should be kept dry and ventilated to prevent aging of rubber parts and rusting of metal parts.
Ⅳ. Environmental Adaptation and Standardized Operation Ensure Smooth Operation
Severe environments and non-standard operations are the main factors accelerating the aging process of equipment. If the dust concentration goes beyond 10 mg/m³, one should install a pulse jet bag dust collector, placing sealing hoods at the inlet and outlet to minimize the dust that might get into the bearings and motor precision components. In a moist environment, with relative humidity over 85%, the metal parts like casings and buckets should be coated with epoxy resin anti-rust paint, and moisture-proof heating is arranged in the motors. During operation, one must adhere to no-load starting and uniform feeding principles. The feeding should not be more than 10% of the rated value. Stopping with a load is also forbidden since overloading may damage the material, causing bucket breakage or casing deformation.
Ⅴ. Regular Comprehensive Overhaul Eliminates Potential Hidden Dangers
The disassembly-style comprehensive periodic overhaul is carried out every half year. Check the degree of bending of the transmission shaft (the allowable is 0.2 mm/m). The bent transmission shaft should be straightened. The welded casing seams are subjected to a sealing test; if leaks are found, the seams are re-welded and treated against corrosion. The sensitivity test of the electrical control system, e.g. overload protection and limit switches, is done; allowable response time is 0.5 seconds. The precision inspection of the equipment should be done once a year in partnership with a qualified external organization. It is aimed at calibrating key parameters, such as conveyor belt deviation and chain tension, to eliminate possible failures.
Through the above multi-dimensional collaborative management, the equipment failure rate can be effectively reduced, and the average service life of bucket elevators can be extended from 3-5 years to 8-10 years, significantly improving production stability and economic benefits.
Bucket Elevator,Bucket Conveyor
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