Bucket Conveyors
Bucket conveyors, also known as bucket elevators, are material handling devices that move bulk materials and various other substances vertically from a lower level to an upper level or from an upper level to a lower level. They are labor saving pieces of equipment designed to increase efficiency and save time. The process for bucket conveyors includes bucket-like containers that scoop and dump bulk substances. Although they are sometimes referred to as elevator conveyors, bucket conveyors differ from elevator conveyors in their appearance and design.
As with all forms of conveyors, bucket conveyors are part of material handling systems and are designed to move products from one place to another. They are a special form of conveying system that is designed to transport bulk materials, such as grains, food, and mined minerals. The design of bucket conveyors enables them to handle a wide assortment of bulk materials efficiently, easily, and conveniently. The resilience, strength, and durability of bucket conveyors are a few of the reasons they are so popular.
The distinctive characteristic of bucket conveying systems is their vertical orientation, which is unlike traditional belt conveyors. The main function of bucket conveyors is moving granular materials that are difficult to carry. The buckets or scoops of bucket conveyors are designed to carry grains, powders, and chunks of raw materials from one location to another location. They have low capacity with strong sturdy walls to avoid breakage and the spoilage of bulk materials.
How Bucket Conveyors Work
Bucket conveyors consist of a series of aligned buckets that are attached to a belt or chain, somewhat like a traditional conveyor. The buckets for a bucket conveyor have a scoop shape, which makes it possible for the conveyor to scoop up bulk materials. Strategically placed, the belt or chain of a bucket conveyor moves the buckets to transport bulk materials to another location where, due to the position of the bucket, the materials are dumped by gravimetric force or centrifugal force.
The methods used to categorize and differentiate bucket conveyors are their drive mechanism and their dumping method. The drive mechanisms for bucket conveyors are chain or belt, which are chosen in accordance with the environment of a bucket conveyor and the materials being transported. The dumping mechanisms for bucket conveyors are centrifugal and gravimetric.
Centrifugal Bucket Conveyors
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Centrifugal bucket conveyors are used with abrasive materials and are constructed using highly durable materials. They scoop bulk materials from a boot or inlet and discharge the materials by centrifugal force into a chute.
Gravimetric Bucket Conveyors
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Gravimetric bucket conveyors are referred to as continuous bucket conveyors due to their buckets being spaced to allow for discharge by the force of gravity. They are commonly used for handling crumbly and fragile bulk materials where aeration of bulk materials is necessary.
In addition to the variation in dispensing systems, bucket conveyors vary in accordance with their drive mechanism, which can be a chain or belt drive. The choice of the drive mechanism varies in accordance with the design of the buckets and the materials being transported.
Belt Driven Bucket Conveyors
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Belt driven bucket conveyors use belts with a pulley from which the buckets are suspended. The belt is made up of a series of steel cords that are capable of withstanding the weight of the load. The steel cords are encased in rubber for protection from the environment.
Chain Driven Bucket Conveyors
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Chain driven bucket conveyors have an endless chain with buckets attached using angular bucket holders. Of the two types of drive mechanisms, chain drives are the sturdiest, most reliable, and have the highest cost.
The selection of the drive mechanism for a bucket conveyor is dependent on the temperature of the operating environment, the size of the pieces of bulk material, and how dense the bulk material is. Due to the cost and set up of bucket conveyors, manufacturers work closely with their clients to select a system that best fits a customer鈥檚 specifications.
It is essential that bucket conveyor users be aware of the parameters regarding bucket conveyor selection. One of the key attributes in the selection process is the temperature of the operating environment, which radically differentiates belt bucket conveyors from chain bucket conveyors.
Temperature
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Belt bucket conveyors can operate for many years at temperatures below 130 掳C (266掳F). Although these are the restrictions under normal conditions, belt bucket conveyors can withstand infrequent exposure to higher temperatures. Continuous high temperatures cause the rubber of the belt to harden and crack.
Chain bucket conveyors can operate, without deterioration, at temperatures between 250oC and up to 350o C (482o F up to 662o F). Regardless of their higher cost, the resilience and durability of chain bucket conveyors makes them ideal for any conditions.
Bulk Material Size
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Bulk material sizes vary from a few millimeters up to several hundred millimeters. Belt bucket conveyors include standard and light use ones and ones that can be used for heavy duty applications. Typically, heavy duty belt bucket conveyors can handle materials as large as 25 mm (0.98 in).
The strength and durability of chain driven bucket conveyors is evident in the sizes of the materials they can handle, which can vary from 80 mm up to 120 mm (3.15 in up to 4.72 in). The larger sized materials tend to be coarse and rough, which necessitates the use of more rugged conveyance methods.
Material Density
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As the density of bulk materials increases, their weight of the materials increases, which further differentiates the type of bucket conveyor drive mechanism. The deciding factor is the quantitative measure of the tonnage per cubic millimeter, which can widely vary depending on the type of material. Bucket conveyor manufacturers have conversion charts for all types of bulk materials to help in matching the material density with the correct bucket conveyor.
Advantages of Bucket Conveyors
For several hundred years, bucket conveyors, in various forms, have been used to move materials vertically. In ancient times, they were manually powered to lift water, building materials, and seeds for planting. In the modern era, different forms of motors are used to power bucket conveyors, whether they are centrifugal or continuous.
The key features of bucket conveyors are:
Vertical Transport
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Of the many characteristics of bucket conveyors, vertical transport is the most obvious and the reason for their use. In essence, bucket conveyors are labor saving devices that make the vertical movement of bulk materials easier and more efficient. They relieve the workforce from menial jobs and prevent potential injuries.
Material Handling
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Other methods of vertical conveyance tend to be harmful to materials and workers and lead to waste and injuries. Bucket conveyors provide a gentle and reliable method for moving bulk materials from one level to the next level.
Customization
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One of the reasons that bulk product producers prefer bucket conveyors is the ability of bucket conveyor manufacturers to design a bucket conveyor that perfectly matches a producer鈥檚 requirements from the types of buckets to the materials used to construct the conveyance system.
Maintenance Requirements for Bucket Conveyors
Bucket conveyors have a simple mechanism that operates continuously without the need for human involvement. Like any form of industrial equipment, bucket conveyors require regular maintenance to ensure high-quality performance.
Bucket Inspection
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Due to the rigorous nature of the work performed by bucket conveyors, it is essential that the buckets of conveyors be regularly checked for wear, damage from materials, and placement. When highly abrasive materials are being handled, bucket checks should be scheduled more frequently.
Drive Alignment
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A common factor for all forms of conveying systems is checking belt alignment. In some instances, bucket conveyor manufacturers set up maintenance agreements that include conveyor inspections by bucket conveyor technicians.
Lubrication
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Bucket conveyors are heavy duty industrial pieces of equipment that require lubrication to ensure smooth operation. Regularly scheduled maintenance assists in preventing damage from friction and extends the lifespan of a bucket conveyor.