ACKNOWLEDGEMENT
With great pleasure I take this opportunity to express my heartfelt gratitude to all the
persons who helped me in making this project report a success.
First of all I am highly indebted to Principal, Dr. I. SATYANARAYANA for giving me
the permission to present this project report.
I would like to thank Mr. P.VIJAY KUMAR, Assistant Professor& Head of the
Department (ME), for giving support throughout the period of my study in SIIET. I am grateful
for his valuable suggestions and guidance during the preparation of this project report.
My sincere thanks to project guide MD.Ilyas ahmed, Design Engineer for potentially
explaining the entire system and clarifying the queries at every stage of this project.
My whole hearted thanks to the staff of Mechanical Engineering who co-operated us for the
completion of this project.
.
Last but not the least, I express my sincere thanks to Mr. R. VENKAT RAO, Chairman,
Sri Indu Group of Institutions, for his continuous encouragement.
I also thank my parents and friends who aided me in completion of this report.
B.Abhishek (16507-M-004)
G.Anil kumar (16507-M-014)
R.Yugendhar (16507-M-046)
S.Arun kumar (16507-M-050)
V.Naveen (16507-M-055)
V.Tarun tej paul (16507-M-056)
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ABSTRACT
DESIGN&MANUFACTURING OF BUCKET ELEVATOR
Bucket Elevators:-
The Bucket Elevators set the standard for bucket conveyor systems - combining durable
construction with design, production, fabrication & Optimizations to ensure the best fit for your
Real Time Training. We the BevconWayors Industries Ltd., have an agreement with Meyer
Ltd., to manufacture under license their entire range of bucket elevators, which we present to you
and the same project will be assigned to here for the Academics for their better feature
placement.
Key Features of Simplex Bucket Elevators include:-
Design of High-quality, double-pitch chain with oversized steel rollers and UHMW
stand-off tracks for quiet, trouble-free operation.
Design Of Heavy-duty, oversized bucket pivot pins extend through both side plates of the
chain to protect against bending and breaking.
Design & Analysis of V-Style overlap bucket designs enable direct loading, prevent
product build-up on bucket lips, and eliminate the need for unsanitary brushes or wipers.
Optimizations of the Positive Bucket Control option reduces waste and inefficiency from
spills and jams by maintaining buckets in their proper position throughout the full cycle
in the elevator.
Your choice of mild steel or stainless steel construction, in open or casing frame designs.
Sectional design & Analysis makes it easy to reconfigure your existing system to meet
new requirements.
We always honour our delivery commitments - Quality worth waiting for every time with
Cox & Plant!
Our foreign clients designed machines and systems at require time on the initial design
concept and this is where we require the designers impetus to ensure you order the machine.
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There are five Simplex models to choose from. Bucket Distribution Systems are also available
for free-flowing and non free-flowing materials.
Bucket Elevator
General:-
Bucket Elevators represent one of the most popular systems for mechanical use today for
elevating bulk materials. Their inherent simplicity makes them a popular choice for bulk material
handling and processing applications all over the world. Continuous developments in bucket
shape, head and boot profiles, manufacturing and operating specifications have resulted in the
highly efficient GuttridgeHiload Bucket Elevator range available today.
Specification:-
In general most free flowing materials and many materials with poor flow characteristics can be
successfully handled with a bucket elevator. The rate at which material can be elevated depends
on many factors in addition to the obvious effects of bucket design, capacity and speed. In
particular attention has to be paid to material charge and discharge characteristics.
Standard Features and Options:-
Some standard features and common options are listed below, but we can customise Bucket
Elevators in many different ways to suit customer requirements.
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CONTENTS
Page no
Acknowledgement i
Abstract ii
Contents iv
List of Figures viii
1.INTRODUCTION 1-2
1.1 Description 1
1.2 Typical bulk handling applications 1
2.LITERATURE SURVEY 3-17
2.1 Bucket Elevator Design Operations 3
2.2 Types of bucket elevator based on construction 4
2.3 Casing Installation 5
2.4 Head and Boot section installation 6
2.5 Drive equipment installation 11
2.6 Belt installation 12
2.7 Bucket installation 14
2.8 Ladder and safety caging 14
2.9 Summary 16
2.10 Installation of Maintenance purpose 17
3.OPERATION AND MAINTENANCE 18-22
3.1 General precautions 18
3.2 Operation 18
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3.3 Precautions of initial operation 20
3.4 Normal operation 21
3.5 Maintenance 22
4.SPECIFICATIONS OF BUCKET ELEVATOR 23-26
4.1 Specifications of bucket elevator 23
5.PERFORMANCE ENHANCEMENT 27-33
5.1 Achieving maximum capacity 27
5.2 Use of steel web elevator belt and SJ buckets 30
6.DESIGN OF SHAFTS 34-42
6.1 Classification of stresses 34
6.2 Materials used for shafts 35
6.3 Design of shafts 35
6.3.1 Shafts subjected to twisting moment 35
6.3.2 Shafts subjected to bending moment 36
6.3.3 Shafts subjected to both twisting and bending moment 37
6.3.4 Shafts subjected to fluctuating loads 39
6.4 Shaft calculations 40
7. DESIGN OF BEARINGS 43-47
7.1 Introduction 43
7.2 Classification of bearings 43
7.3 Bearings used in crusher 44
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8.PRO-ENGINEER 48-55
8.1 CAD 48
8.2 Introduction to pro-e 48
8.3 Capabilities and benefits 49
8.4 Features of pro-e 49
8.4.1 Simple and powerful tool 49
8.4.2 Parametric design 49
8.4.3 Feature based approach 50
8.4.4 Parent child relationship 50
8.4.5 Associative and model centric 50
8.5 Pro-e basic design modes 50
8.6 Assembly in pro-e 51
8.7 Modeling pictures 54
9.BUCKET ELEVATOR SAFETY 56-58
9.1 Introduction 56
9.2 CEMA safety guidelines 56
9.3 Maintenance precautions 57
10.MONITORING SYSTEMS 59-65
10.1 Introduction 59
10.2 Belt slip monitoring 59
10.3 Belt alignment monitoring 60
10.4 Bearing temperature monitoring 62
10.5 Multi—hazard monitoring system 63
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10.6 Serial communication sensors 64
10.7 Safety labels 64
REFERENCE 65
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LIST OF FIGURES
FIGURE NAME PAGE NO
1.1 Bucket Elevator in a Feed Mill 2
2.1 Bucket Elevator in a Feed Mill 5
2.2 Foundation of Bucket Elevator 6
2.3 Guying Recommendation for Bucket Elevator 8
2.4 Guying Bracket Design & Rope Selection 9
2.5 Leveling of Head Shaft 10
2.6 Types of Belt Splicing 13
2.7 Typical Arrangement of Ladder & Cage 15
3.1 Rubber Lip in Discharge Throat 21
4.1 – Figure Showing Specifications of a Typical Bucket 25
Elevator
4.2 – Table with Weight Densities of Materials in g/cc 26
5.1 – Bucket Fill Area Comparison 29
5.2 – A Lagged Head Pulley 29
5.3 – Operation of Winged Pulley 30
5.4 - Alan key head bolt complete with view of belt, bucket, 32
Domed washer and nut
6.1 This is the shaft on which torsion and bending analysis has 34
been done
7.1. Single row deep groove ball bearing 44
7.2 Cylindrical roller bearing 45
7.3 Spherical roller bearing 46
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7.4 Tapered roller bearing 47
8.1 Adding of assembly components 53
8.2 Models of bucket elevator 55
9.1 CEMA Safety Labels Placement Guidelines 58
10.1 Sensor Installed at the Elevator Boot Shaft 60
10.2 Belt Speed Sensor Installed on the Elevator Casing to 60
Detect Belt Slip
10.3 Electronic Monitoring Equipment 65
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