"Design and Model of Bucket Elevator": Under The Guidance of

A
Project Report
ON
DESIGN AND MODEL OF BUCKET ELEVATOR
Under The Guidance Of
Prof. Y.D. Patel

Assistant Professor, A. D. Patel Institute of Technology
In partial Fulfillment for the award of the degree
Of
Bachelor of Engineering
In
Mechanical Engineering
Prepared By
UTKARSH AMARAVAT
(080010119001)
Submitted to
A.D. Patel Institute of Technology, New V.V. Nagar
May, 2012
DECLARATION
I, UTKARSH AMARAVAT hereby declare that the report on entitled Design and Model of
Bucket Elevator is a result of my own work and my indebtedness to other work Publications,
if any, have been duly acknowledgment.
Place: - Anand, Gujarat, India
Date: - 6th May, 2012
Utkarsh Amaravat
i
ACKNOWLEDGEMENT
I deem it a privilege to have been the student of Mechanical Engineering stream in A. D.
Patel Institute of Technology, New V. V. Nagar. My heartfelt thanks to Prof. Y. D. Patel, my
project guide who helped me to bring out this project in good manner with his precious
suggestion and rich experience. I gratefully acknowledge my sincere thanks to my friend
Nirav Sathwara for working as Co-partner and all other friends who help me in this project in
such critical situations and make my project memorable.
I hardly thank to my principle sir Dr. R. K. Jain who grant us permission for economic help
for model making also Mr. Karimbhai, Mr. Samirbhai, Mr. Anandbhai, Mr. Sureshbhai, Mr.
Manishbhai, Mr. Harshadbhai, Mr. Mineshbhai, Mr. Yogeshbhai, Mr. Bharatbhai, Mr.
Birenbhai and Mr. Aashishbhai the staffs members of ADIT workshop, without help of them
this work is not possible.
ii
ABSTRACT
In this modern competitive industrial world one can get a step ahead of his competitor by
selection of proper material handling equipment. Material handling process is overhead for
the production but it is heart of any process plant. Still people prefer most advanced material
handling equipment even though they are costly. But cost can be justified after prolonged
usage of that equipment.
Bucket elevator has evolved as advanced material handling equipment in mechanized bulk
material handling industry. The effective use of different type of bucket elevators are
completely depends on its design and type of bulk material. In this report different types of
bucket elevator are discussed along their different parts and the design of centrifugal
discharge bucket elevator with simultaneous buckets for lifting wheat at a certain height is
reported for a particular output rate. Detailed design, CAD parts, coding for the design
procedure of bucket elevator, fabrication related data and future scope of work and at last
satisfactory conclusion is worked out in successive chapters.
iii
LIST OF TABLE
Table No. Table Description Page No.
2.1 Recommendation for selecting bucket elevators 23

2.2 Main characteristics of buckets 26
2.3 Recommendation for selecting bucket Dimension by Maxi-lift 34
3.1 Bill of material for bucket elevator 45
4.1 Design inputs for prototype model 49
4.2 Design outputs for prototype model 49
4.3 Fabrication processes for bucket elevator 51
5.1 Observation table for 10.00 kg of wheat 63
5.2 Observation table for 24.75 kg of wheat 63
iv
LIST OF FIGURE
Figure No. Figure Description Page No.
1.1 Simple belt conveyor 3

1.2 Simple bucket elevator 4
1.3 Parts of simple belt bucket elevator 5
1.4 Belt bucket elevator 6
1.5 Positive discharge bucket elevator 9
1.6 Gravity discharge bucket elevator 10
1.7 Horizontal discharge bucket elevator 11
1.8 Centrifugal discharge bucket elevator 12
1.9 Twin legged discharge bucket elevator 13
1.10 Single and double bucket elevator 14
1.11 High or Super capacity bucket elevator 15
1.12 Bunge Russia Oilseed bucket elevator 17
1.13 New Zealand - Bins plant bucket elevator 17
1.14 Cimbria (Egypt) - Bins plant bucket elevator 18
1.15 Bahrain-Coke calcining plant bucket elevator 18
1.16 Jordan - Fertilizer plant bucket elevator 19
2.1 Diagram to calculate the pole distance 20
2.2 Forces acting during bucket unloading 21
2.3 Diagram to determine the paths of ejection of material from buckets 21
2.4 Effect of bucket width B on io/tb ratio 25
2.5 Diagram for elevator calculation 28
2.6 Diagram for bucket calculation 34
3.1 Bucket 40
3.2 Ball bearing 40
3.3 Belt 41
3.4 Shaft 42
3.5 Pulley 43
3.6 Bucket elevator assembly 45
v
3.7 Mechanism of bucket elevator 46
3.8 Mechanism problem-1 of bucket elevator 47
3.9 Mechanism problem-2 of bucket elevator 47
3.10 Mechanism problem in case study 48
4.1 Side part of bucket 53
4.2 Bend part of bucket 53
4.3 Sheet metal planning for all bucket 53
4.4 Loading and bending moment diagram for upper shaft 56
4.5 Fabricated bucket elevator prototype model 58
5.1 Variation based on lifting height 59
5.2 Variation based on pulley diameter 60
5.3 Variation based on capacity 61
5.4 Variation based on efficiency 62
vi
LIST OF SYMBOLS, ABBREVIATIONS AND
NOMENCLATURE
R Resultant
P, F Forces
Rp Pulley radius
hp Pole distance
ra Bucket circle radius
Bucket angle
Q Capacity
H Lifting height
Wheat density
Belt speed
Dp or dp Pulley diameter
N Rotational speed of pulley
B Bucket width
V Volume
Bb Belt width
tb Bucket pitch
Average coefficient of bucket filling
mrb Linear mass of belt
g Gravitational constant = 9.81
mb Mass of bucket
T Tension
Resistance on take-up pulley
Ksc Scooping resistance
K Safety factor
W Pulley resistance
Coefficient of friction
P Power
Efficiency
Bp Width of pulley
vii
t Pulley rim thickness
L Belt length
C Centre distance
s Allowable shear stress
w Width of key
h Height of key
rh Hub radius
d Inner diameter of bearing
D Outer diameter of bearing
b Width of bearing, Projection of bucket
Co Static load
C Dynamic load
h1 Depth of bucket
Angle of contact
Angle subtended by each common tangent
3.14
viii
TABLE OF CONTENTS
Page No.
Declaration i
Acknowledgement ii
Abstract iii
List of Tables iv
List of Figures v
List of Symbols, Abbreviations and Nomenclature vii
Table of contents ix
1. Introduction
1.1 Material handling equipments 1
1.2 Bucket elevator 5
1.3 Classification of bucket elevator 8
1.4 Application of bucket elevator 15
1.5 Presently installed bucket elevator in abroad 17
2. Design of bucket Elevator

2.1 Bucket elevator geometry 20
2.2 Design input data for bucket elevator 22
2.3 Flow chart for coding of design 35
3. Modeling of elevator
3.1 Introduction of modeling and its significance 39
3.2 CAD parts of bucket elevator 40
3.3 Assembly of bucket elevator 44
3.4 Bill of material 45
3.5 Mechanism of bucket elevator 45
ix
4. Fabrication of prototype
4.1 Selection of prototype dimension 49
4.2 Fabrication of bucket elevator prototype 51
4.3 Selection of power pulley 55
4.4 Bending moment diagram of upper shaft 55
4.5 Problems occurred during fabrication 57
4.6 Fabricated prototype of bucket elevator 58
5. Results analysis
5.1 Effect of operating variables on performance 59
5.2 Result analysis of prototype model 62
6. Scope of further work 64
7. Conclusion 65
Appendix: A xi
Bibliography xxv
x
Chapter 1: INTRODUCTION
1.1. MATERIAL HANDLING EQUIPMENTS
Expressed in simple language, Material handling equipment is relates to the movement,

storage, control and protection of materials, goods and products throughout the process of
manufacturing, distribution, consumption and disposal. One of the definitions given by the
American Material Handling Society is: Materials handling is the art and science of moving,
packaging and storing of substance in any form. To do it safely and economically and
efficiently, different types of tackles, gadgets and equipment are used, when the materials
handling is referred to as mechanical handling of materials.
Material handling also should be considered with in a system context. Rarely, if ever, are
activities performed in a one area or department of a facility without having an impact on
other operations. Example: The efficiency of store room will affect the efficiency with which
the production operations are performed out on the shop floor. The positioning of conveyor
line in plant might improve material flow through the facility or it could present a hindrance
to plant traffic. A significant improvement in the efficiency of one operation, without a
corresponding improvement in a subsequent step in the work sequence, may only result in a
piling up of materials down the line.
These simple examples illustrates the point that to maximize overall productivity of the plant
or warehouse, the material handling steps that supports production, order assembly, and other
operations must be integrated in to a system of activities rather than being viewed as a
number of isolated independent procedure. In addition to considering time and place utility
and system approach, a through definition of material handling must also include the human
aspect. People are always a part of material handling weather the operation is simple one,
involving only a few items of equipment, or a large, complex, automated system.
Maintenance personnel keep the equipment working properly and keep downtime to a
minimum. Foremen and supervisors oversee overall operations, making sure they meet the
objectives of the department or plant. Training in operating procedure, and in safety practice,
is usually required to make handling operation pay off as expected.
1
Finally, the definition of the material handling must contain an economic consideration.
Certainly the delivery of parts and materials to a specific time, it not completely meaningful
unless accomplished at an acceptable cost so that an adequate return is realized. Material
handling is a system or combination of methods, facilities, labour, and equipments for
moving, packaging and storing of materials to meet specific objectives. A materials handling
operation can be simple and small, and involve only few pieces of basic equipments. Or, it
may be large, complex or automated. Material handling equipment is generally separated into
four main categories.
Storage and handling equipment.
Engineered systems.
Industrial trucks.
Bulk material handling.
Bulk material handling is an engineering field that is cantered around the design of equipment
used for the handling of materials such as ores, coal, cereals, wood chips, sand, gravel and
stone in loose bulk form. It can also relate to the handling of mixed wastes. Bulk materials
handling plants and processes quite often require the elevation (lifting) of bulk materials to
other parts of the plant or process. Numerous technologies and equipment are currently
available for this purpose to the designer and practitioner. Generally they are classifying in to
three main categories.
Pneumatic conveyor or air lifter.
Conventional screw conveyor.
Bucket elevator.
Conveyor is almost universal in application. It can travel for miles at speeds up to 5.08 m/s
and handle larger amount of weight in metric tons with the help of belt. It can also operate
over short distances at speeds slow enough for manual picking, with a capacity of only a few
kilograms per hour. Generally they are use in inclined position and not preferable for vertical
transport. However, it is not normally applicable to processing operations, except under
unusual conditions. Belt conveyors inside the plant may have higher initial cost than some
other types of conveyors and, depending on idler design, may or may not require more
maintenance. However, a belt conveyor given good routine maintenance can be expected to
outlast almost any other type of conveyor. Thus, in terms of cost per ton handled, outstanding
2
economy records have been established by belt conveyors. However, these methods of
elevation can experience a range of problems and limitations, such as in case of:
Pneumatic conveying or lifting:

Relatively high operating costs e.g. blower and compressor
Product velocities and wear rates especially for dilute-phase conveying.
Screw conveying:
Relatively high operating speeds due to slippage between the screw flight and
particles and also due to the back-flow of material through the screw flight and
casing clearance,
Increased particle attrition,
Undesirable casing or screw contact.
Figure 1.1: Simple belt conveyor

(Source: www.enviro-abrassion.com)
3
Bucket elevator is a type of vertical or inclined transport equipment that efficiently moves
goods between floors, vessel or other structure. Elevator is generally powered by electrical
motors that either drive traction cables or counterweight system like a hoist or pump
hydraulic fluid to raise a cylindrical piston like jack. Generally it is preferred for short in
distance compared to belt conveyor. It is more preferable to transport the materials vertically.
The detail explanation of bucket elevator is given in next chapter.
Figure 1.2: Simple bucket elevator

(Source: www.swo-conveyors.com)
4
1.2. BUCKET ELEVATOR
Bucket elevators are the simplest and most dependable units for making vertical lifts. They
are available in a wide range of capacities and may operate entirely in the open or be totally
enclosed. The trend is toward highly standardized units, but for special materials and high
capacities it is wise to use specially engineered equipment. Main variations in quality are in
casing thickness, bucket thickness, belt or chain quality, and drive equipment. The main
purposes of bucket elevators are used to lift bulk materials from one height to another. They
are a reliable and well-proven piece of equipment. The various major parts of bucket elevator
are shown in figure.
Inspection
Relief
Bridge tree panel
vent
Head Boot
Motor
pulley pulley Casing
Take-up
Hood assembly
Head Boot
section section
Friction
material
Belt
Bucket Discharge Boot

Boot
bearing
Short trucking Adjustable
throat plate Boot inlet
Figure 1.3: Parts of simple belt bucket elevator

(Source: www.BEUMER.com)
5
The detail description of various parts of bucket elevators is discussed bellow. The major
components of belt bucket elevator are
Drive head
Bottom head
Inlet
Outlet
Buckets
Casing
Drive unit
Take up
Drive head
Drive unit
Or Motor
Outlet
Bucket Casing
Take-up
Inlet
Figure 1.4: Belt bucket elevator

(Source: www.motridal.com)
6
Drive Head and Bottom Head: Drive head section made with high thickness steel sheets
heavily stiffened. Steel split upper cover easily removable for inspection and maintenance of
drive pulley or wheels. Dust or relief vent on top and inspection panel located at some height
of the outlet. Bottom head is made with high thickness steel sheets is equipped with a
removable bolted door for inspection and cleaning.
Inlet and Outlet: Openings prearranged for the connection with other machines; chutes lined
with wear resistant material when required.
Buckets: On the basis of the conveyed material characteristics the buckets are generally
made of:
Carbon steel
Wear resistant steel
Stainless steel
Plastic material
Buckets are made with bent and welded steel plates, properly reinforced with welded plates
in wear resistant material for heavy duty application, drawn or pressed for light materials.
The buckets are also available in various sections, which are listed below.
Square
V
Trapezoidal
Circular
Casing: It is the cover part of elevators which is made of welded and bolted sections,
designed to obtain a self supporting structure of the machine for the vertical loads. The
assembling sections are done by bolted flanges, with seals between each section. There is a
bolted door for easy bucket inspection and mounting.
Drive Unit: This configuration may vary depending on the application. The typical drive unit
for installed power of 22kW or more includes an electric motor, hydraulic coupling and right
angle gearbox with backstop and torque arm directly mounted on the drive shaft. Additional
7
electric motor for creeping can be installed, upon request, on the gearbox. As an alternative,
drive units can be equipped with a belt drive between electric motor and gear unit.
Take-Up: The gravity take-up system of the bucket elevators is equipped with additional
dust-tight seals between the casing and the guide of the idle shaft belt bucket elevators
realised for heavy duty application are equipped with a self aligning system which ensure the
safe parallel guidance of the pulley.
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.
1.3. CLASSIFICATION OF BUCKET ELEVATOR

Generally bucket elevators are classified in mainly two types.
Belt type bucket elevator.

Chain type bucket elevator.
Now a day there are many types of bucket elevators are available and each one is different
from other according to their feature, application, and design. The major classifications of
bucket elevators are as follows.
bucket elevator
according to according according depending depending
type of to types of to types of
discharge leg bucket use on load on capacity
positive single single low low
gravity twin double medium medium
horizontal heavy heavy
centifugal
8
1. Positive Discharge Bucket Elevator
These types of bucket elevators are widely used for elevating light, fluffy, fragile materials
like free flowing powders and granular products in a range of industries in vertical as well as
inclined position. Buckets are mounted at a well spaced interval, are loaded by digging
material from the boot or by feeding the material in to them. After passing over head wheels,
the buckets are inverted over the discharge spout, providing a positive discharge material.
Generally they have higher conveying capacity. Figure shows the typical diagram of positive
discharge bucket elevator.
Figure 1.5: Positive discharge bucket elevator

(Source: www.fmctechnologies.com and www.rexnord.com)
2. Gravity or Continuous Discharge Bucket Elevator:
In these types of elevators head shafts are fixed, the foot shafts takes up are screw type.
Gravity takes are available. This elevator consists of a series of steel made buckets mounted
on spigot pins between two chains or on the belt with the help of special types of screw. Also
some time the buckets are mounted continuously on the normally friction surface belts.
9
Continuous type steel buckets are used leaving minimum clearance between the buckets. The
buckets retain the material being carried and travelled vertically, until they are mechanically
tipped at discharge positions. Gravity discharge elevators supplied as close bucket discharge
type, central discharge type, or Idler wheel discharge. Generally a slow speed design gravity
bucket elevator is primarily installed for elevating large lumpy, free-flowing material,
sluggish material and abrasive material. Our standard units are usually chain driven, either
friction drive or toothed sprocket. These elevators offer reliability with minimum wear & a
positive discharge emptying of the bucket. The figure shows the vertical arrangement of
gravitational discharge bucket elevator.
Figure 1.6: Gravity discharge bucket elevator

(Source: www.integratedbulksystems.com.au and www.swrewconveyor.com)
3. Horizontal Discharge Bucket Elevator
These elevators are designed and engineered to conform to general practice in the handling of
grain. In particular they are found in flour mills and animal feed mills, where whole grain is
being transferred into intake silos. Also these types of bucket elevators are widely used for
10
elevating aggregate, hard rock, coal from mine in vertical horizontal as well as inclined
horizontal position. Head and foot shafts are provided with roller bearings. Buckets are made
of steel and mounted on the belt with special types of screw. Casing of steel are welded and
dust tight. The curve hood is designed for proper discharge of the grain. The boot can be
loaded from the front or back side or both. Generally they have higher conveying capacity.
Figure shows the typical diagram of horizontal discharge bucket elevator.
Figure 1.7: Horizontal discharge bucket elevator

(Source: www.ryson.com)
4. Centrifugal Discharge Bucket Elevator
Centrifugal elevators are the most common type of elevator installed to most industries
supplied in both belt type and chain type depending on material characteristic and the
capacity being elevated and in some case the feeding method of the elevator. Centrifugal
discharge type elevators are offered as boot take up and head take up. In this types of bucket
elevators buckets are mounted on chain or belt and will handle free-flowing materials with
small to medium size lumps. The standard inlet chute and standard curved bottom plate direct
the material into the buckets and reduce the digging action. The speed of the elevator is
11
sufficient to discharge the material by centrifugal force. The feed point is lower, loading is
simpler and fewer buckets are required than for the Continuous Type Bucket Elevator.
Buckets on chain or belt travel at speeds high enough to discharge materials by centrifugal
force as they pass around the head pulley or sprocket. Bucket spacing and speed is important
for centrifugal discharge bucket elevators. Usually buckets are made from malleable iron.
Generally these types of bucket elevators are more preferable in grain industries.
Figure 1.8: Centrifugal discharge bucket elevator

(Source: www.screwconveyor.com and www.go4b.com)
12
5. Twin Leg Bucket Elevator
The twin lagged or double trunk legging bucket elevator has been designed and engineered to
provide efficient high capacities for handling various grains, feeds, mill stock and similar free
flowing granular materials. The elevator is self-supporting with extra large heads and boot
pulleys. They are fabricated from heavy gauge steel and are dust and waterproof and with
provision for easy clean out. It is manufactured in many different sizes to suit individual
requirements. It has double trunk legging construction with connecting angles provided on
each 10 foot flange section. Vertical angle supports are included on taller units.
Figure 1.9: Twin legged discharge bucket elevator

(Source: www.screwconveyor.com, www.integratedbulksystems.com.au and www.rexnord.com)
13
6. Single and Double Bucket Elevator
The construction of these types bucket elevators are same as other types accept that the
number and types of buckets are use is different. The capacity of double bucket elevators is
more compare to single bucket elevator and also high capacity motor is required in operation.
The size of double bucket elevator is large compare to single bucket elevator since two
buckets are use in one raw as shown in figure. The double bucket elevators are used lift heavy
materials and also where, the higher output is required. Generally these types of bucket
elevators are used in aggregate plant, hard rock plant, cement plant where the lift of heavy
material is possible.
Figure 1.10: Single and double bucket elevator
(Source: www.screwconveyor.com and www.indiamart.com)

14
7. High or Super Capacity Bucket Elevator
Super capacity bucket elevators are a continuous discharge type with buckets mounted
between two strands of chain or on the belt. This type of elevator is used where higher
capacities, severe service or higher shaft centres are required. The high or super Capacity
Bucket Elevators are designed to provide efficient high capacities for handling various grains,
feeds, mill stock and similar free flowing granular materials. It is manufactured in many
different size stop suit individual requirements. It has double trunk legging construction with
connecting angles provided on regular interval flange section. Vertical angle supports are
included on taller units.
Figure 1.11: High or Super capacity bucket elevator

(Source: www.feedandgrain.com and www.screwconveyor.com)
1.4. APPLICATION OF BUCKET ELEVATOR
For stable work and application widely bucket elevator are used. By using this one should get
high Productivity. This bucket elevator is normally designed and made for metallurgy,
15
chemical industry, building materials, mine, pulp and paper industries, ports and terminal,
grain and vegetable oil, food, fodder, plastic and medicine related application. Bucket
elevator systems are used for the following industrial fields.
Cement factories: For lime, clay gypsum, clinker and cement additives like pyrite,
silicate, oxide etc
Environment and water treatment: Waste for combustion, biomass, sludge, ashes
etc.
Power plant: For coal, lignite and desulphurization product like gypsum, ashes,
sludge.
Fertilizers and Chemical: For raw materials and additives handling, phosphate,
nitrate.
Steelworks and Aluminium smelter: For coke, ashes, blast furnace slag, coke,
alumina, crushed bath, covers material.
Food industry: For sugar, flour, vegetables pulp, slaughterhouse waste etc.
Z type bucket chain material elevator is Suitable for lifting puffed food, fried food, nuts,
sugar, candy, hardware, medicines and so on. It is easy to operate fast transfer speed with low
noise. For grain or Seed application bucket elevator are used. This bucket elevator can be
equipped multi-channel explosion-proof mouth if required which can prevent dust explosion.
The system of speed monitoring, automatic running deviation alarm, anti-blockage alarm also
can be equipped to ensure the good running.
Reliable Quality Chain Bucket Elevator is designed and made for metallurgy, chemical
industry, building materials, mine, grain and vegetable oil, food, fodder, plastic and medicine
application. The life is long, inflow feeding, none excavating with hopper and there is few
extrusion and collision circumstance between materials. There is little materials sprinkling
during feeding and discharging to reduce machinery abrasion.
Structure Simple Bucket elevator is used for perpendicular transport the grain, powder and
disperse materials, and suitable for the oil, animal feed and chemical industry etc. This
Bucket Elevator is a fixed elevator categorized as feeding device of delivering powdery and
granular materials upward vertically. It has simple structure, smaller cover are, short
16
shipping route and low pollution. Wood chips are received from belt conveyor by a double
led centrifugal discharge bucket elevator and delivered to a distributed belt conveyor over
silos.
1.5. PRESENTLY INSTALLED BUCKET ELEVATORS IN ABROAD:
Bunge Russia recently opened a new oilseed extraction facility featuring Brock steel bins.
Bucket elevator
Figure 1.12: Bunge Russia Oilseed bucket elevator

(Source: www.World-Grain.com)
Chief Industries installed two bins to increase storage capacity by 16,000 tonnes at this plant
in New Zealand.
Bucket elevator
Figure 1.13: New Zealand - Bins plant bucket elevator

17
Cimbria recently installed bins with a combined storage capacity of 333,000 tonnes at seven
facilities in Egypt.
Bucket elevator
Figure 1.14: Cimbria (Egypt) - Bins plant bucket elevator

Figure 1.15: Bahrain - Coke calcining plant

18
Figure 1.16: Jordan - Fertilizer plant
19
Chapter 2: DESIGN OF BUCKET ELEVATOR
2.1. BUCKET ELEVATOR GEOMETRY:
Pole Distance:
Figure 2.1: Diagram to calculate the pole distance

(Source: Spivakovsy, A.O. and Dyachkov, V.K. (1985), Conveying Machine, MIR Publication,
Forth Edition)
As a bucket revolve on the pulley, the resultant R of the forces P and F varies in magnitude
and direction. If however, the resultant force vector is prolonged to the vertical line passing
through the pulley centre, it turns out that at any position of the bucket, and vector R
intersects the vertical in one and the same point B to the pulley centre O is called the pole
distance. The pole distance is denoted by hP.
Bucket Unloading:
At lower speed of the pulley, the effect of the gravity force on unloading become stronger
and hP increases. When hP is not larger than rP the pole is inside the pulley circle (figures 2.2a
and 2.2b), the centrifugal force is much higher than the gravity force and hence bucket
unloading centrifugally.
20
(a) Centrifugal unloading; (b) gravity unloading; (c) Combined unloading
Figure 2.2: Forces acting during bucket unloading
Forth Edition)
Similarly if hP grater than rP the force of gravity is large and buckets are unloaded
gravitationally. With rP < hP ra unloading of combined types takes place. Therefore, the
method of unloading is determined by the ratio between the pole distance and pulley radius
A= hP /rP .
Trajectory of Partials Discharged From a Bucket:
Figure 2.3: Diagram to determine the paths of ejection of material from buckets
Forth Edition)
21
As a bucket moves around the top pulley, a particle of load in it is acted upon by the gravity
force, centrifugal force, and inertia force due to the relative acceleration of sliding the particle
on the bucket wall.
The path and velocity S of sliding particle can be determined by solving equation of motion
of the particle. The start of the motion of the particles depends on the method of unloading.
With centrifugal discharge the load beings to move in the bucket at an angle 0 = 15-300. For
elevators with centrifugal or combined unloading, it may be taken that 0 = 30-450
2.2. DESIGN INPUT DATA FOR BUCKET ELEVATOR:
Assumption:
During design of bucket elevator a few factors are consider for design and based on this for
input data whole design calculations were carried out. The following factors are considered
during design.
Material for lifting: Wheat

Average bulk density: 720-768 Kg/m3
Application: In flour mills to transmitting large amount of wheat from ground floor
to required destination (floor).
Properties of material: Lighter than metal, Injection moulded, Flexible, Thick
corners and digging lip.
Specific requirements: It should have excellent chemical resistance and it should
have higher transmission capacity.
Calculation:
Capacity (Q) = 30.00 Tonne/hour
Lifting height (H) = 3.00 m
Wheat density () = 0.768 Tonne/m3
22
1. THE MAIN CHARACTERISTICS OF THE ELEVATOR
By using Table 2.1 a belt elevator with widely spaced deep buckets and belt speed = 3.20
m/s is suitable for the transmission purpose. We select a four-ply belt; then the diameter of
the drive pulley is given by DP = 125 * 4 = 500 mm = 0.50 m and its radius r P = 0.25 m. The
rotational speed of the pulley at = 3.20 m/s is given by,
60.00
N=
( Dp )
60.00 3.20
=
( 0.50 )
= 122.23 rpm
122.00 rpm
The pole distance hp is found by the formula,
g r 2 30.002
hp =
2 r 2 N 2
895.00
=
N2
895.00
=
122.002
= 0.06 m
Table 2.1: Recommendation for selecting bucket elevators
AVERAGE SPEED m/s
KIND TYPE
TYPICAL TYPE COEFFICIENT OF
OF OF
EXAMPLE OF ELEVATOR OF BUCKET
LOAD BUCKET BELT CHAIN
FILLING
LOW SPEED
PULVERIZED
GRAVITY D 0.85 - 0.6 - 0.8
COAL
UNLOADING
DRY HIGH SPEED

CEMENT, ROCK, 0.80
PULVERIZED CENTRIFUGAL D 1.25 - 2.0 -
PHOSPHET MEAL
MATERIAL UNLOADING
GRAIN HIGH SPEED
PRODUCTS CENTRIFUGAL OR
(FLOUR) GRAVITY S 0.85 1.0 - 2.0 -
UNLOADING
HIGH SPEED
CENTRIFUGAL OR
FOOD GRAIN D 0.75 2.0 - 3.2 -
GRAVITY
UNLOADING
23
SAWUST, WOOD
GRANULAR CHIPS, DRY
AND FINE - CLAY IN LUMPS, DITTO D 0.8 1.25 - 2.0 1.0 1.6
LUMP, LOW MILLED PEAT,
ABBRASIVE FINE COAL
LOW SPEED
LIME, SOOT GRAVITY D 0.8 - 0.4 1.0
UNLOADING
PULVERIZED
AND HIGH SPEED
SOIL, SAND,
GRANULAR, CENTRIFUGAL OR
POWDER CHALK, S 0.6 1.0 - 2.0 0.8 2.0
WET GRAVITY
CHEMICALS
POORLY UNLOADING
FLOWING
(Note: Bucket types: D: Deep, S: shallow)

Forth Edition)
At lower speeds of the pulley the effect of the gravity force on unloading becomes stronger
and hp increases. Now when hp is not longer than rp, i.e. the pole is inside the pulley circle as
shown in figure 2.1, the centrifugal force is much higher than the gravity force; particles of
the material in a bucket are displaced to the external (front) of the bucket and later are
unloaded centrifugally. With hp greater than rp i.e. with the pole being the front edge of
buckets as shown in figure the force of gravity is large compared with the centrifugal
component and the buckets are unloaded by gravity over their back wall (closest to the
pulley). Since hp<rp the buckets can be unloaded centrifugally. Therefore the method of
bucket unloading is determined by the ratio between the pole distance and pulley radius. Now
by using Formula at = 0.75 we have,

io tb =
3.60
30.00
=
3.60 3.20 0.768 0.75
= 4.52 m1
24
(Note: Buckets types: M: Shallow, D: Deep, V: V-shaped, R: Round bottom)
Figure 2.4: Effect of bucket width B on io/tb ratio
Forth Edition)
Now by referring Table 2.2, we chose for io/ tb = 5.0 deep type buckets with Bucket width (B)
= 250 mm, Volume (V) = 21.00 mm3, Belt width (Bb) = 300 mm, Bucket pitch (t b) = 400 mm
and also io = 2.0 lit.
With these characteristics of buckets and the belt speed 3.20 m/s, the rated throughout
capacity of 30 t/h can be obtained at the coefficient of bucket filling,
25
Table 2.2: Main characteristics of buckets
Belt width
Bb for Deep bucket Deep bucket
belt elevator Pitch type type Pitch Bucket with side guide
Bucket mm of D S of
width B widely closely
mm spaced spaced
bucket bucket V - shaped Round
st nd tb mm tb mm type bottom
1 2 io io/tb io io/tb V type R
Raw raw lit m-1 lit m-1
io io/tb io io/tb
lit m-1 lit m-1
100 125 - 200 0.2 1.0 0.1 0.5 - - - - -
125 160 150 220 0.4 1.3 0.2 0.66 - - - - -
160 200 - 320 0.6 2.0 0.35 1.17 160 0.65 4.06 - -
200 250 - 400 1.3 3.24 0.75 1.87 200 1.3 6.5 - -
250 300 315 400 2.0 5.0 1.4 3.5 200 2.0 10.0 - -
320 370 400 500 4.0 8.0 2.7 5.4 250 4.0 10.0 6.4 25.6
400 450 500 500 6.3 12.6 4.2 8.4 320 7.8 24.4 14 43.7
500 550 600 630 12.0 19.0 6.8 10.8 400 - - 28 70
650 700 - 630 16.8 26.0 11.5 18.2 500 - - 60 120
800 - - - - - - - 630 - - 118 187
1000 - - - - - - - 630 - - 148 235
(Note: Bucket types: D: Deep, S: shallow)

Source: Spivakovsy, A.O. and Dyachkov, V.K. (1985), Conveying Machine, MIR Publication,
Forth Edition)
Q tb
=
3.6 io
30 0.4
=
3.6 3.20 0.768 2.0
= 0.678
Which is possible to reduce the speed to 1.36 m/s but it is substandard and cannot ensure
centrifugal discharge.
26
2. LINEAR GRAVITY FORCE
The linear mass of the belt with four-ply of material like rubber ground is given by, mrb =
2.40 m/s then,
qrb = g mrb
= 9.81 2.40
= 23.54 N/m
24.00 N/m
The mass of standard deep bucket of Bucket width (B) = 250 mm, is given by mb = 3.38 Kg
than,
mb
qo = qrb + g
tb
3.38
= 24.00 + 9.81
0.4
= 106.89 N/m
The useful load is given by,
gQ
ql =
3.60
9.81 30.00
=
3.60 3.20
= 25.55 N/m
Then the total linear gravity force acting on the carrying runs is given by,
q = qo + ql
= 106.89 + 25.55
= 132.44 N/m
27
3. PULL CALCULATION
(a) Elevator scheme; (b) Diagram of belt tension

Figure 2.5: Diagram for elevator calculation
Source: Spivakovsy, A.O. and Dyachkov, V.K. (1985), Conveying Machine, MIR Publication,
Forth Edition)
According to the diagram of tension Figure 2.5(b), the lowest tension of the belt should be
expected at point 1. We can make only a rough calculation, since we do not know the tension
T4 in the belt section running off the drive pulley as required to ensuring the rated pull. We
assume that T1 = T0. The tension at point 2 is found by considering the resistance on take-up
pulley and the scooping resistance by formula for heavy-duty operation = 1.08 and Ksc = 2.0
T2 = T1 + Wsc
= T1 + Ksc ql
= 1.08 T0 + 2 25.55
= 1.08 T0 + 51.10
28
T3 = Ton = T2 + q H
= 1.08 T0 + 51.1 + 132.44 3
= 1.08 T0 + 448.42
Calculation against the direction of belt motion gives,
T4 = Toff = T1 + H qo
= T0 + 106.89 3
= T0 + 320.67
According to theory of frictional drives we have,
Dp dp
= sin 1
2C
= sin 1 0 ... (Since Dp = dp)
=0
Now angle of contact/arc of contact/angle of lap is given by
=+20
= rad
Ton Toff e or for the case considered T3 T4 e
For a mild steel pulley and high humidity (the elevator operates outdoor), the friction
coefficient = 0.35, so that at = rad. Therefore e = 3.00. Hence, T3 3.00 T4 or for
the case considered
1.08 T0 + 448.42 3.00(T0 320.67)
Solution of this equation gives T 0 >> - 267.49 N. To ensure the certain margin, we take T 0 = 0
N and then,
29
T4 = Toff = T0 + 320.67
= 320.67 N
321.00 N
T3 = Ton = 3.00 T4
= 3.00 320.67
= 962.01 N
962.00
The required number of belt plies is found for Kop = 55 N/mm and safety factor K = 10
K Smax
i=
Bb Kop
10 962.00
=
30 55.00
= 0.58
Noting that belt is weakened by bolts and should ensure firm fastening of buckets, we can use
the four-ply belt adopted earlier in the calculation. The circumferential force on the drive
pulley, noting the pulley resistance is,
T3 T4
W=

962.01 320.67
=
1.08
= 596.83 N
= 564.00 N
The power of drive motor, assuming the efficiency of drive mechanism = 0.85 and a margin
K = 1.25, will be
KW
P=
1000
30
1.25 593.83 3.20
=
1000 0.85
= 2.79 kW
2.8 kW
Hearse, we take finally a drive motor of a power P = 2.8 kW and rotational speed N = 51.95
rpm
4. PULLEY CALCULATION
Width of the pulley is given by,
Bp = 1.25 Bp
= 1.25 300
= 375.00 mm
Thickness of rim is given by,
Dp
t= +2
200
500
= +2
200
= 5.5 mm
6.0 mm
5. BELT CALCULATION
Length of belt is given by,
(Dp + dp ) (Dp dp )2
L= 2H+ + +C
2 4
(0.512 + 0.512) (0.512 0.512)2
= 2 3.00 + + + 3.00
2 4
= 7.60 m
31
Belt Tension,
Dp
T = T3 T4
2
0.50
= (962.01 320.67)
2
= 160.34 Nm
160.00 Nm
Permissible Tension in belt per mm width (f),
T3
f=
Bb
962.01
=
300
= 3.21 N/mm
6. SHAFT CALCULATION
For 300 mm belt width and 500 mm pulley diameter, Diameter of shaft (d) is 83 mm.
Allowable shear stress for shaft and key material (mild steel), sk = 70.4 N/mm2 then,
allowable shear stress for shaft accounting keyway effect,
s = 0.75 sk
= 0.75 70.4
= 52.80 N/mm2
Now, Equivalent torque acting on shaft,
d3
Te = sk
16
833
= 52.8
16
= 5998.85 103 Nmm
32
= 5.9 KN m
Width of key,
d
w =
4
83
=
4
= 20.83 mm
21.00 mm
Height of key,
2w
h=
3
2 21
=
3
= 13.89 mm
14 mm
Length of key = 22 mm and radius of hub is equal to diameter of shaft so, r h = 83 mm
7. BEARING CALCULATION
By using series: 60
Inner diameter: d = 83 mm
Outside diameter: D = 130 mm
Width of bearing: b = 23 mm
Static load: Co = 42 KN
Dynamic load: C = 49 KN
Permissible rpm for grease = 5187.5 rpm and
For oil = 6536.25 rpm
33
8. BUCKET CALCULATION
Figure 2.6: Diagram for bucket calculation

(Source: www.maxilift.com)
By using Table 2.3 given by

Depth of bucket, h1= 156.00 mm
Projection of Bucket, b= 156.00 mm
Table 2.3 Recommendation for selecting bucket Dimension by Maxi-lift

Width of Bucket Projection of Bucket Depth of Bucket
B, mm b, mm h1, mm
108 79 79
133 105 105
159 105 105
184 105 105
181 130 133
206 130 133
232 130 133
238 156 156
264 156 156
289 156 156
(Source: www.maxilift.com)
34
Now, assume =18
h1 h2 = b tan 18
= 156 0.325
= 50.70 mm
h2 = h1 (h1 h2 )
= 156.00 50.70
= 105.30 mm
105.00 mm
Therefore, Number of buckets = Belt length Bucket pitch

= 7.60 0.40
= 19
2.3. FLOW CHART FOR CODING OF DESIGN
Start
Lifting Height (H) in m =
Wheat Density in Tonne/m3 =
No. of Belt ply (Np) =
Efficiency =
35
No Yes
Want to enter
Capacity (Q)?
Enter i0/tb in m-1 Capacity (Q) t/hr =
Q = i0/tb * 3.60 *v * * I0/tb = Q / (3.60 * v * * )
No Want to enter Pulley Yes
diameter?
Dp = 125 * No. of Belt ply Pulley Diameter (Dp)

mm
rp = Dp / (2000), m
Belt velocity (V) = 3.2 m/s
N = 60 * v * 1000 / ( * Dp), rpm
hp = 895 / (N2)
No Unloading of bucket
hp < rp
centrifugally is not possible
Yes
Unloading of bucket centrifugally is possible Stop
Bucket width (B) in mm

Belt width (Bb) in mm
Bucket pitch (tb) in mm
Bucket volume (V) = (21* B) / 250 mm3
36
mrb = 2.4 * Np / 4;
qrb = 9.81 * mrb;
mb = 3.38 * B / 250;
q0 = qrb + (9.81 * mb * 1000 / tb);
Tension T4 in N = q0*H;
Tension T3 in N = 3.00*T4
Safety factor k = 10
Required no. of belt plies (i) = k * T3 / (Bb * 55);

Pulley Resistance (W) in N = (T3 - T4) / 1.08
Motor power (P) in kW = 1.25 * W * 3.2 / (1000 * Efficiency)
Pulley width (Bp ) in mm = 1.25 * Bb
Rim thickness (t ) in mm = Dp / 200 + 2
Belt length (L) in m = 2 * H + (3.14 * Dp / 1000)
Belt tension (T) in Nm = (T3 - T4) * Dp / 2
Permissible Tension (f) in belt per mm width in N/mm = T3 / Bb
Projection of bucket (b) in mm

Depth of Bucket (h1) in mm
(h1 - h2) = b * tan(18)
h2 = h1 - (h1 - h2), mm
n = L * 1000 / tb
37
Shaft diameter (d) in mm
Shaft load in kN
Bearing No.
Bearing bore diameter in mm
Bearing outside diameter in mm
Bearing width in mm
Bearing static load (C0) in kN
Bearing dynamic load (C) in kN
Permissible rpm for Grease lubrication
Permissible rpm for Oil lubrication
Radius of hub (rh) in mm
Key width (w) in mm
Key height (h) in mm
Equivalent torque acting on shaft (Te) in Nmm
Stop
38
Chapter 3: MODELING OF ELEVATOR
3.1. INTRODUCTION OF MODELING AND ITS SIGNIFICANE
Modeling is defined as the complete representation of an object or a system with the

graphical and non graphical information. It is also known as geometric modeling. It generates
the mathematical description of the geometry and non geometry of an object or a system in
the computer database and the image of an object or system on the graphic screen. With the
use of modeling the designer constructs the graphical image of an object on the computer
screen with the use of following three types of commands to the computer.
1. Generates basic geometric elements such as points, lines and circles etc.
2. To accomplish scaling, rotation or other transformation of various elements.
3. Which cause various elements to be joined?
There are various types of drawing required in different field of engineering and science. In
the field of mechanical engineering, the drawing of machine components and layouts are
prepared. In the field of civil engineering, plans and layouts of power distribution system are
prepared. The use of CAD process provides enhance graphics capabilities which allows any
designer to,
1. Conceptualize his/her ideas

2. Modify the design very easy
3. Perform animation
4. Make design calculations
5. Use colours, fonts and other aesthetic features.
Significance of modeling is as follows:

1. It makes the model a true replica of actual objects.
2. As the model is stored in mathematical form, the model modification can be carried
out easily.
3. A geometric model can be use to evaluate the various properties of an actual objects.
4. A geometric model provides a sophisticated tool for 3D visualization of the objects.
39
5. A geometric model can be easily converted in to the two-dimensional views.
6. A geometric model can be used by Pro/Engineer software to perform the different
types of analysis such as: stress-strain analysis, kinematic analysis, dynamic analysis,
thermal analysis etc.
7. A geometric model can be used by the CAM software to generate a complete tool
path required for the automatic manufacturing.
3.2. CAD PARTS OF BUCKET ELEVATOR:
The important parts of bucket elevator are as under,
1. Bucket
Command used:
Extrude 1: Make solid cube of 250 x 156 x 156 mm.

Extrude 2: Draw side view of bucket on Extrude 1 and remove excess material.
Shell 1: Remove inside material of Extrude 2, so finally bucket shape is generated.
Pattern 1 of hole 1: Make one hole of 15 mm diameter and done direction pattern for
75 mm distance.
Function:
Buckets are used to carry grain material from bottom to top.
Figure 3.1: Bucket Figure 3.2: Ball bearing
40
2. Ball bearing
Command used:
Revolve 1: Generate sphere of 4.27 mm radius by using revolve command.
Revolve 2: Generate Bearing inside and outside ring shape of 83 mm inside diameter
and 130 mm outside diameter of 23 mm width.
Assembly: Finally done assembly of sphere and bearing ring shape assembly and put
16 spheres between inside and outside ring by using axis pattern. So finally Bearing is
generated.
Function:
Bearing is used to reduce friction and to convert sliding contact in to rolling contact.
3. Belt:
41
Figure 3.3: Belt
Command used:
Extrude 1: Make side part of belt and Extrude it up to 300 mm, So finally Belt shape
is generated.
Pattern 1 of hole 1: Draw first hole of 15 mm diameter and done curve pattern at 400
mm distance.
Pattern 2 of hole 2: Draw second hole of 15 mm diameter at distance 75 mm to first
hole and done curve pattern at 400 mm distance.
Pattern 3 of hole 3: Draw third hole of 15 mm diameter at distance 150 mm to first
hole and done curve pattern at 400 mm distance.
Function:
Belt is used to carry bucket and drive driven pulley (bottom pulley) by using driving
pulley (top pulley).
4. Shaft
Figure 3.4: Shaft
Command used:
Extrude 1: Draw 83 mm diameter circle and extrude it up to 600 mm length. So
finally shaft shape is generated.
42
Extrude 2: Draw cube of 22 x 21 x 17 mm on shaft at 143 mm distance from centre to
both side on opposite axis and done Extrude remove material to generate key way on
shaft.
Function:
Shaft is used to transmit power, motion and torque.
5. Pulley
Figure 3.5: Pulley
Command used:
Extrude 1: Generate 22 x 21 x 14 mm cube as key.
Assembly 1: Put key on shaft key way and made shaft-key Assembly.
Revolve 1: Generate hub shape of 166 mm outside radius and 83 mm inside radius
with 48 mm total height and revolve it to get hub rough shape.
Round 1: 5 mm fillet action are done at end of hub shape for its smoothness.
Extrude 2: Generate cube of 8.63 x 21 x 45 mm cube is generated on inside part of
hub shape and done Extrude remove material to generate key way in hub.
Assembly 2: Combine hub and shaft-key assembly.
Assembly 3: Put Bearing inside hub in previous done assembly.
Extrude 3: Draw ring of 83 mm inside diameter and 130 mm outside diameter and
extrude it to 6 mm, to generate bearing cover.
Assembly 4: Assemble bearing cover on bearing in Assembly 3 outcome.
43
Extrude 4: Draw ring of 142 mm inside diameter and 500 mm outside diameter and
extrude it to 6 mm, to generate pulley cover plate.
Assembly 5: Assemble pulley cover plate on hub in Assembly 4 outcome.
Extrude 5: Generate 500 mm inside diameter, 6 mm thickness and 375 mm pipe as
pulley rim.
Assembly 6: Assemble pulley rim on cover plate in assembly 5 outcome, so finally
get Pulley.
Function:
Pulley is used to transmit power, motion and torque from one shaft to another shaft by
using belt.
3.3. ASSEMBLY OF BUCKET ELEVATOR:
Used Top to Bottom assembly approach to assemble bucket elevator as shown in figures
earlier. Various steps includes in assembly of bucket elevator are as followed. The final
figure of assembly of bucket elevator is shown in figure 3.6
Assembly 1: First call pulley at top and give fix constrain to it and take direction
pattern of the same at distance of 3000 mm
Assembly 2: Call belt and fix it on two pulleys.
Assembly 3: Call buckets and fix it on belt by using nut bolts, And finally done curve
pattern of bucket at 400 mm distance to get final bucket elevator assembly.
44
Figure 3.6: Bucket elevator assembly
3.4. BILL OF MARERIAL
Table 3.1: Bill of material for bucket elevator
Serial Number Quantity Description Material

1. 19 Bucket Mild steel
2. 1 Belt Rubber
3. 2 Pulley Mild steel
4. 4 Bearing Stainless steel
5. 4 Hub Mild steel
6. 4 Key Mild steel
7. 4 Cover plate Mild steel
8. 2 Shaft Mild steel
3.5. MECHANISM OF BUCKET ELEVATOR
The mechanism of bucket elevator is prepared by performing various stapes for that it
required various joints between two respective parts. Joints required for mechanism is applied
45
during assemble the parts. Various joints required for mechanism are pin joint, sliding joint,
belt joint. The detail procedure for mechanism is discussed under with the required figure.
First off all call the support on which the driving or driven pulley is going to be fixed
and apply fixed constrain on it and take the direction pattern of the same at required
distance.
Call the driven pulley and assemble it with lower end support by pin joint. Same
procedure is followed during assemble of driving pulley.
Than call the belt bucket assembly and assemble it on outer surface of the pulley by
sliding joint.
Now go to the mechanism and apply the servomotor between the pin joint of support
and driving pulley and give required input for rotation of servomotor in servomotor
definition as shown in figure 3.7
Figure 3.7: Mechanism of bucket elevator
Click on the analysis definition and select the type of analysis also give the required
input for respective analysis and run it. Here we select the kinetic analysis.
During mechanism of belt elevator various problem occurred due to sliding joint of belt and
pulley. Such problems occurred during mechanism are as under.
46
Problem: 1
From the figure 3.8 both pulleys are assembled by pin joint and belt is assembled by sliding
joint, but during running of mechanism the driven pulley joint is suppressed and remain
steady and driving pulley is rotate with belt like a clock hand.
Figure 3.8: Mechanism problem-1 of bucket elevator
Problem: 2
From the below figure 3.9 both pulley are assembled by pin joint and belt is assembled by
sliding joint, but during running of mechanism one pulley joint is suppressed and driven
pulley remain steady and driving pulley is rotate but the belt slides out from the both pulley
surface.
Figure 3.9: Mechanism problem-2 of bucket elevator
47
To solve these problems, A belt drive as a case study is considered and parts are modeled
using Pro/Engineer and the same problems are persisting in that assembly of mechanism. But
same problem occurred during the mechanism of belt joints. In short the simulation of the
belt-pulley system using Pro/Mechanism yet to be work out for its implementation in bucket
elevator mechanism.
Fig. 3.10: Mechanism problem in case study
48
Chapter 4: FABRICATION OF PROTO TYPE
4.1 SELECTION OF PROTOTYPE DIMENSION:
Selection of dimension for prototype model is based on the input and output parameter of the
C program shown in Appendix: A. The input and output data for the dimension of prototype
model is shown in following tabular format.
Input data:
Table 4.1: Design inputs for prototype model

Lifting Height (H) - m 1
Wheat Density () - Tonne/m3 0.768
Number of belt ply 4
Efficiency 0.85
Want to enter Capacity (Q)? (Y/N) N
Enter value of i0/tb (1.3, 2.0, 3.24, 5.0, 8.0) - m-1 2.0
Want to enter Pulley diameter (Dp)? (Y/N) Y
Pulley diameter (Dp) - mm 200
Output data:
Table 4.2: Design outputs for prototype model

Capacity (Q) - Tonne/hr 13.271040
Pulley radius (rp) - m 0.1
Belt velocity (v) - m/s 3.2
Rotation speed of pulley (N) - rpm 305.732483
Pole Distance (hp) - m 0.001875
Unloading of bucket centrifugally is possible? Y
Bucket width (B) - mm 160
Belt width (Bb) - mm 200
49
Bucket pitch (tb) - mm 320
Bucket volume - mm3 13.44
Tension (T3) - N 234.262802
Tension (T4) - N 78.087601
Required no. of belt plies 0.212966
Pulley Resistance (W) - N 144.606674
Motor power - kW 0.783039
Pulley width (Bp) - mm 250.000000
Rim thickness (t) - mm 3.000000
Belt length (L) - m 2.628000
Belt Tension (T) - Nm 17971.919922
Permissible Tension (f) in belt per mm width - N/mm 1.347894
Projection of bucket (b) - mm 79
Depth of Bucket (h1) - mm 79
h2 mm 47.80
No. of bucket (n) 8.212500
Shaft diameter (d) - mm 30
Shaft load - kN 6
Bearing No. 6006
Bearing bore diameter - mm 30
Bearing outside diameter - mm 55
Bearing width mm 13
Bearing static load (C0) - kN 8.30
Bearing dynamic load (C) - kN 13.30
Permissible rpm for Grease lubrication 12000
Permissible rpm for Oil lubrication 15000
Radius of hub (rh) - mm 30
Key width (w) - mm 7.500000
Key height (h) - mm 5.000000
Equivalent torque acting on shaft (T e) - kNm 0.279774
50
4.2. FABRICATION OF BUCKET ELEVATOR PROTOTYPE
After getting the above program output for prototype model design, fabrication of the model
is carried out. Various processes involved in fabrication of the prototype model are as under.
Table 4.3: Fabrication processes for bucket elevator

1. Cutting 6. Centering 11. Welding
2. Marking 7. Turning 12. Bending
3. Punching 8. Chamfering 13. Chipping
4. Drilling 9. Gas cutting 14. Boring
5. Facing 10. Grinding 15. Slotting
The procedure followed for the fabrication of model is as followed:
For support structure:

1. Cut the L - channel, flat stripes of required height and length for the structure.
2. Marking and punching on each channel and flat stripes as per need of location of hole.
3. Drill on each punching location as per requirement of hole diameter with the help of
drilling machine with respective drilling tool of 10 mm and 12 mm diameter.
4. By using bolts of 12 mm and 10 mm diameter at required hole joining various
sections and make whole structure.
For pulley shaft:

1. Cut the 32 mm diameter shaft as per the requirements of length.
2. Face the both end of shaft on lathe and centre on each end with the drilling tool.
3. Turning the whole shaft (both shaft) of 30 mm diameter.
4. Chamfer the each end of the shaft.
For pulley:
1. Cut the 200 mm diameter, 6 mm thick pipe in two equal lengths of 250 mm for pulley
rim.
2. According to the inner diameter of the pipe cut the four round circles for cover plate
with the help of gas cutting.
51
3. Grind the outer surfaces of the plates to match with the inner surface of pulley rim.
4. Drill the hole of 30 mm diameter on centre of each cover plate.
5. Weld the cover plates on both shafts; two cover plates on each shaft.
6. Fix the pulley rim on shaft-cover plate assembly at required position and make just tag
welding.
7. Check the proper fixing the pulley rim on the shaft-cover plate assembly carried out
the full welding.
For buckets:
As per the calculation of the requirements of bucket, calculate the plate size of by developing
the whole bucket as shown in figure 4.1 & 4.2 and calculate the area of sheet required for the
one bucket. Prepare a bucket sheet metal planning for all buckets which is shown in figure
4.3.
1. As per the bucket sheet metal planning makes a marking on sheet.

2. Cut the plates in required shape for side parts (small in size) and bend parts (large in
size) of the bucket with the help of tin snip.
3. Bend the large size of sheet in bending machine.
4. Cut the side parts (small in size) of the bucket in required shape.
5. Weld the bend parts of bucket with side parts.
6. Carried out grinding operation for batter surface finish.
7. Marking and punching on the surface on which the buckets are going to be bolt on the
belt and drilling on that desired location with required drill tool.
Calculation for material utilisation is as follows (Refere figure 4.3),
52
Figure: 4.1: Side part of bucket
Figure: 4.2: Bend part of bucket
Figure: 4.3: Sheet metal planning for all bucket

53
Area of front part, A = 231.13 164
= 38889.32 mm2
Area of front part, A = 105 105

= 11025 mm2
Total area of front part and side part is 9A mm2 and 18B mm2 respectively. Now total
material used is given by,
C = 9A + 18B
= 9 38889.32 + (18 11025)
= 548453.88 mm2
Total area available of sheet, D = 1800 + 750

= 2550 mm2
Now, material utilization factor is given by,
Area used C
MUF = =
Total area available D
548453.88
=
2550
= 40%
From the above calculation it is cleared that, only 40% of sheet is used from the whole sheet.
So, in place of using whole sheet, use of scrap of particular size is advisable and also
economical.
For belts:
1. Marking on the belt for fixing the buckets at required bucket pinch distance.
2. Mark the holes position on this bucket pitch distance.
3. Punching on that holes location with the help of dot punch.
4. Drill the all punched marks on belt with hand drilling machine.
54
Assemble the all parts which are fabricated earlier with the help of suitable joints like nut-bolt, weld
etc. the final picture of bucket elevator is shown in figure 4.4.
4.3. SELECTION OF POWER PULLEY
To reduce the motor speed up to 305 rpm, it is necessary to use an extra pulley (power
pulley) in conjunction with upper shaft of bucket elevator. For that calculation is necessary,
calculation for speed reduction is given below.
Where,
D = Diameter of top power pulley attach with upper pulley of bucket elevator
d = Diameter of bottom power pulley attack with motor
N = Top power pulley speed = 305 rpm
n = Bottom power pulley speed = 1400 rpm
1400
=
305
= 4. 59
To get this Diameter ratio, take D = 22.86 cm = 9 inch and d = 5 cm = 1.96 inch 2 inch
4.4. BENDING MOMENT DIAGRAM FOR UPPER SHAFT
Bending moment at point X and B are,
Mx = Ra(170)
= 4076.95 Nmm
Mb = 18.639 210
= 391.42 Nmm
55
Bending moment diagram is shown in figure 4.4. Now, calculation for required length of v
belt is shown as under.
C = Distance between two pulleys = 89 cm

D = Diameter of top power pulley attach with upper pulley of bucket elevator = 22.86 cm
d = Diameter of bottom power pulley attack with motor = 5 cm
Figure: 4.4: Loading and bending moment diagram for upper shaft
56
Now,
(D + d) (D d)2
L = 2C + +
2 4C
(22.86 + 5) (22.86 5)2
= 2(89) + +
2 4(89)
= 222.656 cm
= 87.65 inch
4.5. PROBLEMS OCCURE DURRING FABRICATION
The following problems ware faced during the fabrication of prototype model of bucket
elevator.
1. Due to spring back effect in bucket sheet material, Elastic recovery occurs when press
machine pressure is released. It is depends on type of material, thickness of material,
band radius and band angle.
2. For pulley, used hollow pipe of 200 mm diameter, 6 mm thickness as pulley rim, this
is slightly oblong during turning process. So to overcome this problem made pulley
assembly like fabricated shaft, cover plate and pulley rim, than again done turning on
pulley rim.
3. Purchased shaft from scrap so doesnt know about its material property. Because of
this purchased harden shafts machining is not possible. So replaced it by purchasing
new shaft to get desired property of shaft material so once can machined it properly
with in limited constraints.
4. Delay in getting of belt and pulley machining (Done outside due to less capacity of
machine of ADIT workshop).
5. Problem due to pulley shaft alignment, Because of this belt is comes outside form
pulley. To avoid this weld required thickness of strips or flange on pulley so that belt
is fitted in required space and run within specific path.
57
4.6. FABRICATED PROTOTYPE OF BUCKET ELEVATOR
Figure: 4.5: Fabricated bucket elevator prototype model

58
Chapter 5: RESULTS ANALYSIS
5.1. EFFECT OF OPERATING VARIABLES
For the purpose of handling, the effects of various operating conditions are being studied
theoretically for working of bucket elevator.
Effect of lifting height on number of bucket, motor power and belt length:
Assume capacity (Q) = 30 Tonne / hr and Pulley Diameter (D p) = 500 mm as constant, than
the effect of lifting height on number of bucket, motor power and belt length is shown in
graph bellow. As the lifting height of bucket elevator increases the number of bucket, motor
power and belt length is gradually increases (Refer figure 5.1).
90
80
70
60
50
40
30
20
10
0
3m 6m 9m 12 m 15 m
No. of Bucket 19 34 49 64 79
Motor Power (kW) 2.8 5.6 8.4 11.2 13.9
Belt Length (m) 7.6 13.6 19.6 25.6 31.6
Figure 5.1: Variation based on lifting height

59
Effect of pulley diameter on speed, belt length, number of bucket, and shaft diameter:
Assume lifting height (H) = 3 m and capacity (Q) = 30 Tonne / hr as constant, than the effect
of pulley diameter on speed, belt length, no. of bucket, and shaft diameter is shown in graph
bellow. As the pulley diameter of bucket elevator increases the rotational speed of bucket
elevator is decreases gradually and the belt length is increases. The number of bucket remains
almost constant but the diameter of shaft slowly increases (Refer figure 5.2).
350
300
250
200
150
100
50
0
200 250 300 400 500
Roatational speed (rpm) 305.58 244.46 203.72 152.79 122.23
Belt Length (m) 6.63 6.79 6.94 7.26 7.57
No. of Bucket 17 17 17 18 19
Shaft Diameter (mm) 40 50 60 80 100
Figure 5.2: Variation based on pulley diameter

60
Effect of capacity on bucket width, bucket volume, belt width, bucket pitch, motor
power and number of bucket:
Assume lifting height (H) = 1.5 m and pulley diameter (D p) = 250 mm as constant, than the
effect of capacity on bucket width, bucket volume, belt width, bucket pitch, motor power and
number of bucket is shown in graph (Refer figure 5.3). As the capacity of bucket elevator
increases the bucket width increases and hence the volume of bucket increase as its
dimensions of bucket increases, the belt width also increases. As the capacity increases the
bucket pitch increases but the motor power and number of required buckets decreases.
450
400
350
300
250
200
150
100
50
0
8.63 13.3 21.5 30
Bucket width (mm) 125 160 200 250
Bucket volume (mm3) 10.5 13.3 16.8 21
Belt width (mm) 160 200 250 300
Bucket pitch (mm) 220 320 400 400
Motor Power (kW) 1.14 1.02 1.02 1.24
No. of Bucket 17 12 10 10
Figure 5.3: Variation based on capacity

61
Effect of efficiency on motor power:
Assume lifting height (H) = 1 m, pulley diameter (Dp) = 200 mm capacity (Q) = 13.3 Tonne /
hr as constant, than the effect of efficiency on motor power is shown in graph bellow. As the
efficiency of bucket elevator increases the motor power decrees gradually (Refer figure 5.4).
0
0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1
Motor Power (Kw) 5.78 2.89 1.93 1.45 1.16 0.96 0.83 0.72 0.64 0.57
Figure 5.4: Variation based on efficiency
5.2. RESULT ANALYSIS OF PROTOTYPE MODEL
Observation:
Actual rotational speed of bucket elevator = 320 rpm
1 bucket capacity = 0.95 kg so, for 9 bucket capacity = 8.55 kg
Case: 1
In this case bucket elevator is completely empty means no wheat inside the elevator for
scooping effect on starting and wheat is finished during feeding without checking of scooping
capacity for bucket elevator.
62
Table 5.1: Observation table for 10.00 kg of wheat
Wheat inside
Wheat at Wheat inside
the elevator Wheat at
inlet for the elevator Time Efficiency
before starting outlet
feeding after closing (Second) (%)
of scooping (kg)
(kg) (kg)
(kg)
10.00 0.00 4.50 5.50 48.48 45.00
Case: 2
In this case 5.5 kg of wheat is already remaining of case: 1 inside the bucket elevator to see
scooping action from starting of feeding and feeding of wheat is finished within 1 min and
after 1 min for 20.31 second bucket elevator run without feeding of wheat at inlet just to see
the complete scooping action and switch off the power when scooping effect is finished.
Table 5.2: Observation table for 24.75 kg of wheat

Wheat inside
Wheat at Wheat inside
the elevator Wheat at
inlet for the elevator Time Efficiency
before starting outlet
feeding after closing (Second) (%)
of scooping (kg)
(kg) (kg)
(kg)
19.25 5.50 18.00 6.50 80.31 72.72
63
Chapter 6: FUTURE SCOPE OF WORK
The velocity analysis can be carried out to understand its effect with change in bucket
angle.
Coding of the C Program can be refined for its faster and efficient way of its usage
while editing input parameters. Use of fopen, fclose functions i.e. file operations using
C- program will simplify the editing of the input and programming length. This leads
to modular programming for bucket elevator. Existing program coding takes 325 lines
results in difficulty of program modification and may be erroneous results.
The mechanism of bucket elevator is not completed yet due to problem regarding to
belt connection as a joint using Pro/Mechanism. The simulation of the bucket elevator
assembly should be carried out to predict instantaneous velocity and components of
the velocities in the required directions. Moreover, Torque and power calculations can
be obtained using the dynamic simulation considering the gravity effect also. The
obtained results can be compared with the practical one to understand the differences
and subsequent remedial actions. The frictional considerations will be incorporated
during the mechanism simulation along with gravity effect to predict the system
behaviour more realistic.
The effect of clearance between the bucket elevator belt mechanisms along with its
outer casing will be lucrative to analyze for further improvement of its performance.
The throttle plate arrangement for the prototype outlet will be more suitable for the
existing configuration.
The take-up system of the bucket elevators is equipped with additional dust-tight seals
between the casing and the guide of the idle shaft belt bucket elevators realised for
heavy duty application are equipped with a self aligning system which ensure the safe
parallel guidance of the pulley.
An idler mechanism should be also provided for tightening belt during running of
bucket elevator.
64
Chapter 7: CONCLUSION
1. This project was designed to study the design of bucket elevator also enhance the
manufacturing idea about the processes and fabrication of the equipment.
2. Through this experience, we found the chance to apply our knowledge of previous
courses like machine design, Kinematics of machinery, Product Design and Value
Engineering.
3. The designed bucket elevator works having certain limitations.
4. When designing the system, we should make sure the material is cost effective,
and durable. In the meantime, it should also be available in the market.
5. Dimensions should be realistic.
65
APPENDIX: A
PROGRAM:
/* Program about Bucket Elevator Design */
#include<stdio.h>
#include<conio.h>
void main()
{
clrscr();
intNp, Dp, B, Bb, tb, b, h1, d, yes, no, Shaft_load, Bearing_No, Bearing_bore_diameter,
Bearing_outside_diameter, Permissible_rpm_for_Grease_lubrication, Permissible_rpm_for_Oil_lubrication, rh;
float H, Density, Bp, Q, a, ratio, v, rp, N,n,f, hp, V, mrb, qrb, mb, q0, T3, T4, k=10, i, W, Efficiency, P, t, L, T,
h2, C0, C, w, h, Te;
printf("Lifting Height(H) in m = \n");
scanf("%f", &H);
printf("Wheat Density in Tonne/m3 = \n");
scanf("%f", &Density);
printf("No of Belt ply (Np) = \n");
scanf("%d", &Np);
printf("Efficiency = \n");
scanf("%f", &Efficiency);
printf("Want to enter Capacity (Q)? Enter 1 for yes and 0 for no- \n");
scanf("%d",&yes);
{
if(yes)
{
printf("Capacity (Q) in Tonne/hr = \n");
scanf("%f", &Q);
a=Q/(3.60*3.2*Density*0.75);
{
if(1.1<=a<=1.3)
{
printf("ratio (i0/tb) in m-1 = 1.3 \n");
ratio = 1.3;
}
else if(1.4<=a<=2.0)
{
ratio = 2.0;
xi
}
else if(2.1<=a<=3.24)
{
ratio = 3.24;
}
else if(3.25<=a<=5.0)
{
ratio = 5.0;
}
else if(5.1<=a<=8.0)
{
ratio = 8.0;
}
else if(8.1<=a<=12.6)
{
ratio = 12.6;
}
else
printf("out of range.");
}
}
else
{
printf("Enter value of ratio (i0/tb)- (1.3, 2.0, 3.24, 5.0, 8.0, 12.6) in m-1 = \n");
scanf("%f", &ratio);
Q=(ratio*3.60*3.2*Density*0.75);
printf("Capacity (Q) in Tonne/hr = %f \n", Q);
}
}
printf("Want to enter Pulley diameter (Dp) or Want to use equation Dp=125*Np? Enter 1 for yes and 0 for no-
\n");
scanf("%d",&yes);
{
if(yes)
{
xii
printf("Pulley diameter (Dp) in mm = \n");
scanf("%d", &Dp);
}
else
{
Dp=125*Np;
printf("Pulley diameter (Dp) in mm = %d \n", Dp);
}
}
rp=(float)Dp/(2*1000);
printf("Pulley radius (rp) in m = %f \n", rp);
N=(float)60*3.2*1000/(3.14*Dp);
printf("Belt velocity (v) in m/s = 3.2 \nRotation speed of prlley (N) in rpm = %f \n", N);
hp=(float)9.81*Q*Q/(3.14*3.14*N*N);
printf("Pole Distance (hp) in m = %f \n", hp);
{
if(hp<rp)
{
printf("Unloading of bucket centrifugally is possible. \n");
{
if(ratio==1.3)
{
printf("Bucket width (B) in mm = 125 \nBelt width (Bb) in mm = 160 \nBucket pitch (tb) in mm = 220 \n");
B=125;
Bb=160;
tb=220;
}
else if(ratio==2.0)
{
B=160;
Bb=200;
tb=320;
}
else if(ratio==3.24)
{
B=200;
Bb=250;
xiii
tb=400;
}
else if(ratio==5.0)
{
B=250;
Bb=300;
tb=400;
}
else if(ratio==8.0)
{
B=320;
Bb=370;
tb=500;
}
}
V=(float)21*B/250;
printf("Bucket volume in mm3 = %f \n", V);
mrb=2.4*Np/4;
qrb=9.81*mrb;
mb=3.38*B/250;
q0=qrb+(9.81*mb*1000/tb);
T4=(float)q0*H;
T3=(float)3.00*T4;
printf("Tension T3 in N =%f \nTension T4 in N = %f \n", T3,T4);
i=(float)k*T3/(Bb*55);
printf("Safety factor k = 10 \nRequired no. of belt plies (i) = %f \n", i);
W=(float)(T3-T4)/1.08;
printf("Pulley Resistance (W) in N = %f \n", W);
P=(float)1.25*W*3.2/(1000*Efficiency);
printf("Motor power (P) in kW = %f \n", P);
Bp=(float)1.25*Bb;
printf("Pulley width (Bp) in mm = %f \n", Bp);
t=(float)(Dp/200)+2;
printf("Rim thickness (t) in mm = %f \n", t);
L=(float)2*H+(3.14*Dp/1000);
printf("Belt length (L) in m = %f \n", L);
T=(float)(T3-T4)*Dp/2;
xiv
printf("Belt Tension (T) in Nm = %f \n", T);
f=(float)T3/Bb;
printf("Permissible Tension (f) in belt per mm width in N/mm = %f \n",f);
{
if(108<=B<=120)
printf("Projection of bucket (b) in mm =79 \nDepth of Bucket (h1) in mm = 79 \nh2 in mm = 47.08 \n");
else if(121<=B<=180)
else if(181<=B<=235)
else if(236<=B<=320)
printf("Projection of bucket (b) in mm =156\n Depth of Bucket (h1) in mm = 156 \nh2 in mm = 92.98 \n");
else
printf("out of range. \n");
}
n=(float)L*1000/tb;
printf("N0. of Bucket (n) = %f \n", n);
if(Bb==160 &&Dp==200)
{
printf("Shaft diameter (d) in mm = 25 \nShaft_load in kN = 5 \nBearing_No = 6005 \nBearing_bore_diameter in
mm = 25 \nBearing_outside_diameter in mm = 47 \nBearing_width in mm = 12 \nBearing static load (C0) in kN
= 6.55 \nBearing Dynamic load (C) in kN = 11.20 \nPermissible_rpm_for_Grease_lubrication = 15000
\nPermissible_rpm_for_Oil_lubrication = 18000 \n");
d=25;
}
else if(Bb==200 &&Dp==200)
{
d=30;
}
else if(Bb==250 &&Dp==200)
{
xv
d=35;
}
else if(Bb==160 &&Dp==250)
{
d=35;
}
else if(Bb==300 &&Dp==200)
{
printf("Shaft diameter (d) in mm = 40\n Shaft_load in kN = 8 \nBearing_No = 6008 \nBearing_bore_diameter in
d=40;
}
else if(Bb==200 &&Dp==250)
{
d=40;
}
else if(Bb==160 &&Dp==300)
{
d=40;
}
else if(Bb==250 &&Dp==250)
{
xvi
d=45;
}
else if(Bb==200 &&Dp==300)
{
d=45;
}
else if(Bb==160 &&Dp==350)
{
d=45;
}
else if(Bb==300 &&Dp==250)
{
printf("Shaft diameter (d) in mm = 50 \nShaft_load in kN = 10 \nBearing_No = 6010 \nBearing_bore_diameter
in mm = 50 \nBearing_outside_diameter in mm = 80 \nBearing_width in mm = 16 \nBearing static load (C0) in
kN = 16.00 \nBearing Dynamic load (C) in kN = 21.60 \nPermissible_rpm_for_Grease_lubrication = 8500
d=50;
}
else if(Bb==160 &&Dp==400)
{
d=50;
}
else if(Bb==370 &&Dp==200)
{
xvii
d=55;
}
else if(Bb==250 &&Dp==300)
{
d=55;
}
else if(Bb==200 &&Dp==350)
{
d=55;
}
else if(Bb==300 &&Dp==300)
{
d=60;
}
else if(Bb==200 &&Dp==400)
{
d=60;
}
else if(Bb==160 &&Dp==400)
xviii
{
d=60;
}
else if(Bb==370 &&Dp==250)
{
d=65;
}
else if(Bb==250 &&Dp==350)
{
d=65;
}
else if(Bb==160 &&Dp==500)
{
d=65;
}
else if(Bb==300 &&Dp==350)
{
d=70;
}
xix
else if(Bb==200 &&Dp==450)
{
d=70;
}
else if(Bb==370 &&Dp==300)
{
d=75;
}
else if(Bb==250 &&Dp==400)
{
d=75;
}
else if(Bb==200 &&Dp==500)
{
d=75;
}
else if(Bb==300 &&Dp==400)
{
d=80;
xx
}
else if(Bb==250 &&Dp==450)
{
printf("Shaft diameter (d) in mm = 85 \nShaft_load in kN = 17 \nBearing_No = 6017 \n");
d=85;
}
else if(Bb==370 &&Dp==350)
{
d=90;
}
else if(Bb==300 &&Dp==450)
{
d=90;
}
else if(Bb==250 &&Dp==500)
{
d=90;
}
else if(Bb==300 &&Dp==500)
{
d=100;
}
else
printf("Out of range. \n");
rh=d;
printf("Radius of hub (rh) in mm = %d \n", rh);
w=(float)d/4;
printf("Key width (w) in mm = %f \n", w);
h=(float)2*w/3;
printf("Key height (h) in mm = %f \n", h);
Te=(float)52.8*3.14*d*d*d/16/1000000;
printf("Equivalent torque acting on shaft (Te) in kNm = %f \n", Te);
}
else
{
xxi
printf("Unloading of bucket centrifugally is not possible. \n");
}
}
getch();
}
SAMPLE COMPUTATION:
1. For Bucket Elevator Design:
Input:
Lifting Height(H) in m = 3
Wheat Density in Tonne/m3 = 0.768
No of Belt ply (Np) = 4
Efficiency = 0.85
Want to enter Capacity (Q)? Enter 1 for yes and 0 for no - 1
Capacity (Q) in Tonne/hr = 30
Want to enter Pulley diameter (Dp)? or Want to use equation Dp=125*Np? Enter 1 for yes and 0 for no 0
Output:
Ratio (i0/tb) in m-1 = 5.0
Pulley diameter (Dp) in mm = 500
Pulley radius (rp) in m = 0.250000
Belt velocity (v) in m/s = 3.2
Rotation speed of pulley (N) in rpm = 122.292992
Pole Distance (hp) in m = 0.073231
Unloading of bucket centrifugally is possible.
Bucket width (B) in mm = 250
Belt width (Bb) in mm = 300
Bucket pitch (tb) in mm = 400
Bucket volume in mm3 = 21.000000
Tension T3 in N = 957.946533
Tension T4 in N = 319.315521
xxii
Required no. of belt plies (i) = 0.580574
Pulley Resistance (W) in N = 591.325012
Motor power (P) in kW = 2.782706
Pulley width (Bp) in mm = 375.000000
Rim thickness (t) in mm = 4.000000
Belt length (L) in m = 7.570000
Belt Tension (T) in Nm = 159657.750000
Permissible Tension (f) in belt per mm width in N/mm = 3.193155
Projection of bucket (b) in mm = 156
Depth of Bucket (h1) in mm = 156
H2 in mm = 92.98
No. of Bucket (n) = 18.925001
Shaft diameter (d) in mm = 100
Shaft_load in kN = 22
Bearing_No = 6020
Radius of hub (rh) in mm = 100
Key width (w) in mm = 25.000000
Key height (h) in mm = 16.666666
Equivalent torque acting on shaft (Te) in KNm = 10.362000
2. For Bucket Elevator Prototype:
Inputs:
Lifting Height(H) in m = 1
Wheat Density in Tonne/m3 = 0.768
No of Belt ply (Np) = 2
Efficiency = 0.85
Want to enter Capacity (Q)? Enter 1 for yes and 0 for no - 0
Enter value of ratio (io/tb)- (1.3, 2.0, 3.24, 5.0, 8.0, 12.6) in m-1 = 2.0
Want to enter Pulley diameter (Dp)? or Want to use equation Dp=125*Np? Enter 1 for yes and 0 for no - 1
Pulley diameter (Dp) in mm = 200
Output:
Capacity (Q) in Tonne/hr = 13.271040
Pulley radius (rp) in m = 0.100000
Belt velocity (v) in m/s = 3.2
Rotation speed of pulley (N) in rpm = 305.732483
Pole Distance (hp) in m = 0.001875
xxiii
Unloading of bucket centrifugally is possible.
Bucket width (B) in mm = 160
Belt width (Bb) in mm = 200
Bucket pitch (tb) in mm = 320
Bucket volume in mm3 = 13.440000
Tension T3 in N = 234.262802
Tension T4 in N = 78.087601
Required no. of belt plies (i) = 0.212966
Pulley Resistance (W) in N = 144.606674
Motor power (P) in kW = 0.680502
Pulley width (Bp) in mm = 250.000000
Rim thickness (t) in mm = 3.000000
Belt length (L) in m = 2.628000
Belt Tension (T) in Nm = 15.617
Permissible Tension (f) in belt per mm width in N/mm = 1.171314
Projection of bucket (b) in mm = 105
Depth of Bucket (h1) in mm = 105
H2 in mm = 47.08
No. of Bucket (n) = 8.212500
Shaft diameter (d) in mm = 30
Shaft_load in kN = 6
Bearing_No = 6006
Bearing_bore_diameter in mm = 30
Bearing_outside_diameter in mm = 55
Bearing_width in mm = 13
Bearing static load (C0) in kN = 8.30
Bearing Dynamic load in kN = 13.30
Permissible_rpm_for_Grease_lubrication = 12000
Permissible_rpm_for_Oil_lubrication = 15000
Radius of hub (rh) in mm = 30
Key width (w) in mm = 7.500000
Key height (h) in mm = 5.000000
Equivalent torque acting on shaft (Te) in KNm = 0.279774
xxiv
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xxv
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xxvi

"Design and Model of Bucket Elevator": Under The Guidance of

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"Design and Model of Bucket Elevator": Under The Guidance of

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DESIGN AND MODEL OF BUCKET ELEVATOR

Under The Guidance Of

Prof. Y.D. Patel

In partial Fulfillment for the award of the degree

A.D. Patel Institute of Technology, New V.V. Nagar

Place: - Anand, Gujarat, India

Date: - 6th May, 2012

Table No. Table Description Page No.

2.1 Recommendation for selecting bucket elevators 23

Figure No. Figure Description Page No.

1.1 Simple belt conveyor 3

2. Design of bucket Elevator

6. Scope of further work 64

1.1. MATERIAL HANDLING EQUIPMENTS

Expressed in simple language, Material handling equipment is relates to the movement,

Pneumatic conveying or lifting:

Figure 1.1: Simple belt conveyor

Figure 1.2: Simple bucket elevator

Bucket Discharge Boot

Figure 1.3: Parts of simple belt bucket elevator

Figure 1.4: Belt bucket elevator

1.3. CLASSIFICATION OF BUCKET ELEVATOR

Belt type bucket elevator.

positive single single low low

gravity twin double medium medium

horizontal heavy heavy

Figure 1.5: Positive discharge bucket elevator

2. Gravity or Continuous Discharge Bucket Elevator:

Figure 1.6: Gravity discharge bucket elevator

3. Horizontal Discharge Bucket Elevator

Figure 1.7: Horizontal discharge bucket elevator

4. Centrifugal Discharge Bucket Elevator

Figure 1.8: Centrifugal discharge bucket elevator

Figure 1.9: Twin legged discharge bucket elevator

Figure 1.10: Single and double bucket elevator

(Source: www.screwconveyor.com and www.indiamart.com)

Figure 1.11: High or Super capacity bucket elevator

1.4. APPLICATION OF BUCKET ELEVATOR

1.5. PRESENTLY INSTALLED BUCKET ELEVATORS IN ABROAD:

Figure 1.12: Bunge Russia Oilseed bucket elevator

Figure 1.13: New Zealand - Bins plant bucket elevator

Figure 1.14: Cimbria (Egypt) - Bins plant bucket elevator

Figure 1.15: Bahrain - Coke calcining plant

2.1. BUCKET ELEVATOR GEOMETRY:

Figure 2.1: Diagram to calculate the pole distance

Trajectory of Partials Discharged From a Bucket:

2.2. DESIGN INPUT DATA FOR BUCKET ELEVATOR:

Material for lifting: Wheat

The pole distance hp is found by the formula,

DRY HIGH SPEED

(Note: Bucket types: D: Deep, S: shallow)

125 160 150 220 0.4 1.3 0.2 0.66 - - - - -

500 550 600 630 12.0 19.0 6.8 10.8 400 - - 28 70

650 700 - 630 16.8 26.0 11.5 18.2 500 - - 60 120

800 - - - - - - - 630 - - 118 187

1000 - - - - - - - 630 - - 148 235

(Note: Bucket types: D: Deep, S: shallow)

The useful load is given by,

(a) Elevator scheme; (b) Diagram of belt tension

Calculation against the direction of belt motion gives,

According to theory of frictional drives we have,

Now angle of contact/arc of contact/angle of lap is given by

Q = i0/tb * 3.60 v * I0/tb = Q / (3.60 * v * * )