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Cangilones PDF
DOI 10.1007/s10035-010-0243-2
ORIGINAL PAPER
Abstract This paper presents the results of discrete ele- design of the elevator casing this early discharge may or may
ment simulations applied to a bucket elevator model with not impact on the overall conveying efficiency.
particular reference to the head pulley transition zone. This
is the first stage in a larger study to better understand the Keywords Bucket elevator · Bulk materials ·
mechanics of bucket elevator operation with reference to the Mechanical handling · DEM
discharge of particles at the head end. At the head end two
issues arise; mechanically, the buckets are bolted to the con-
veying media (typically a fabric reinforced belt) and at the 1 Introduction
point of belt to headpulley tangency, the tip of the bucket
undergoes a theoretical step change in velocity. This theoret- Bucket elevators are common industrial devices used
ical step change results in a classical under-damped response throughout bulk materials handling industries. They offer a
in the buckets tip velocity. In undergoing this motion, there compact footprint for the vertical elevation of a wide variety
are stresses that are passed to the carcass of the conveying of bulk materials. There is little restriction on the elevation
media; understanding the magnitude of these stresses is one height, and throughputs are broadly scalable. The mechani-
longer term goal of this research allowing a quantitative basis cal construction of a bucket elevator is relatively simple with
for the existing qualitative design guidelines such as (Hand- most elevators using a fabric reinforced ‘conveyor belt’ mate-
book for conveyor and elevator belting, Apex Belting Pty rial for power transmission and bucket attachment, large ele-
Ltd). The discharge of the bulk material from the bucket has vators may utilise steel core belts, hybrid belts or chain. For
been addressed Beverly et al. (Bulk Solids Handling, 1983) the purpose of this paper, a flexible belt is assumed in the
but this analysis is dependent on simple, but common, bucket construction.
geometry and ignores the initial transition to the headpulley. Typically, buckets are bolted to the belt using a purpose
Ignoring the transition with a low speed discharge elevator is designed bucket elevator bolt with a large diameter head
not likely to impact on the predicted discharge pattern, how- that embeds into the belt cover to provide a flush finish
ever with high speed discharge elevators, the destabilising on the underside of the belt. The buckets generally have a
effect of the transition is expected to promote premature dis- flat inner/back wall through which the fasteners pass and
charge of bulk material from the bucket. Depending on the these determine the effective pivot of the bucket on the belt.
Figure 1 illustrate the shape of a Starco Jumbo bucket and the
mounting of these buckets onto a typical belt (hidden behind
W. McBride (B)
the buckets).
School of Engineering, University of Newcastle, Operationally, the buckets within a bucket elevator pass
University Drive Callaghan, Newcastle, NSW 2308, Australia through the lowermost section of the elevator called ‘the
e-mail: william.mcbride@newcastle.edu.au boot’. The material to be elevated is supplied by chutes
M. Sinnott · P. W. Cleary
on either the downward, or upwards strands of the elevator
CSIRO—Mathematical and Information Sciences, Private Bag 33, located close to the boot end. A percentage of material ele-
Clayton South, VIC 3169, Australia vated will return to the boot through spillage at the head
123
170 W. McBride et al.
123
Discrete element modelling 171
α
Force on
Deformed belt position
Bucket
V=Vbelt
Material in bucket can be 'kicked' out To Tail
and fall down the carry strand. Nominal Belt Tension 'T'
restorative forces have not been decoupled and this is a point CYS Points -
These are
for further research. concurrent in the
simulation
a Vb b
123
172 W. McBride et al.
connection rotational stiffness data. This data was used to initially coloured with vertical bands to indicate the original
calculate the effective spring rates used in the DEM process location of the particles during the discharge cycle. These
as the soft spring case. A “stiff” case with an arbitrary joint particle colours are maintained throughout the simulation
spring constant of 5.0 × 108 N/m was employed to simulate allowing visualization of the materials flow inside the bucket
a much taller elevator. during the discharge cycle. Evident from visual comparison
For the DEM simulations reported here, spherical grains is that the lower spring stiffness promotes earlier material
with diameters in the range 2–10 mm with an equal mass dis- discharge from the bucket, this is best captured by carefully
tribution in each size class were used. The material parame- comparing Fig. 5b, e. In Fig. 5b more material has impacted
ters applied to the particles include a solids density of 1,100 the elevators upper enclosure and more material is commenc-
kg/m3 , a coefficient of friction of 0.5 for particle-particle and ing to drop. The horizontal velocity for many of the particles
particle-boundary collisions, and a coefficient of restitution first discharged (Fig. 5a, d) is insufficient to ensure that they
of 0.5 for particle-particle and particle-boundary collisions. can discharge from the elevator without interactions with
In the set up for this simulation, the bucket is statically other particles or buckets. This is illustrated in images 5c
filled with the bucket located some distance away from the and 5f by the amount of particles that are falling back to the
headpulley. The particle diameters are random within the headpulley and eventually the boot of the elevator. These sim-
constraint of total equal mass in each size range. The veloc- ulations predict 4% of the initial load returned to the boot for
ity of the CYS point is brought to test speed ensuring that any the stiff spring case, and 8% returned with the softer spring
transient motion of either the bucket or particles associated scenario. This is broadly consistent with experimental data
with the acceleration phase of the CYS has abated before the obtained in our laboratories during contract research with
headpulley transition. bucket elevators. In the experimental work a single bucket
was hand loaded with a pre-defined mass of product, with that
bucket a sufficient distance from the head pulley to ensure
4 Results full speed was obtained prior to discharge. Once this bucket
had discharged, the elevator was stopped, isolated, and the
4.1 Bucket discharge observations boot area swept to capture the material that had not exited
the elevators discharge port. This material was weighed to
Figure 5a, b, c present images taken at different times during determine the percentage of carry back per bucket discharge.
the discharge cycle for the soft/low spring stiffness condi-
tion and Fig. 5d, e, f show equivalently timed images for Also evident from Fig. 5, is the poor design of this ele-
the high/stiff spring stiffness case. The bucket’s contents are vators enclosing steelwork with significant material impact
a Soft b c
d Stiff e f
Fig. 5 Comparison of discharge for a low ‘bucket to belt’ spring stiff- tions. The hinge point of the buckets is moving at a velocity of 1.35 m/s
ness of 5 × 106 N/m (a, b, c) and a high ‘bucket to belt’ spring stiffness in a counter clockwise direction. The corresponding tip velocity of this
of 5 × 108 N/m (d, e, f). Gravity is acting vertically down in all simula- simulated bucket is 2.6 m/s equivalent to a radial acceleration of 1.3 g
123
Discrete element modelling 173
a b
Splitter
Fig. 6 Particle interactions with the splitter plate. The splitter geome- lowered by perhaps only 50 mm, the amount of material returned to the
try is identical in each image with 6b at a later time step. From image boot resulting from the splitter would be almost eliminated. Physical
6a an expectation of most particles exiting the discharge opening is experiments on similar bucket elevators in the laboratory have clearly
given, however in 6b it becomes evident that a moderate amount of the illustrated this effect
material is returned to the boot of the elevator. If the splitter plate were
onto the casing itself. This particle impact would affect the
conveying efficiency of the unit, and most likely lead to a α
premature failure of the casing. Some modern high speed
bucket elevators have adopted a volute shaped head casing
to help guide the particles to the discharge. In the case where
head room is critical, or in the optimal design of volute shaped β
casings, Fig. 5 illustrates how the DEM method can be of
value.
Figure 6a, b are provided to illustrate the interaction of the
discharged material with the ‘splitter plate’ with divides the
stream either to the discharge outlet, or back to the boot of
the elevator. Both 6a and 6b are the same geometry with 6b
at a later time step. These images indicate that lowering this
Fig. 7 Bucket angular velocity of the bucket as it traverses the head
particular splitter plate would likely improve this designs effi- pulley. Belt to bucket spring stiffness 5.0 × 106 N/m
ciency as the particles are impacting and the stream is being
physically split by this plate.
123
174 W. McBride et al.
a - Soft b - Stiff
Figure 8a, b illustrate the impact of the simulations ‘bucket pattern predicted from the simulation agrees with the foot-
to belt’ spring constant on the motion of the bucket at entry age collected from the laboratory model, though the lack of a
and exit to the head pulley. The ‘motion’ at time = 1.8 s is the synchronised rotary position reading on the headpulley does
buckets entry to the head pulley and at 2.5 s, the exit from the limit the capacity to provide quantitative comparisons at this
pulley. In Fig. 8a the acceleration trace displays a complex stage.
form for which we offer no explanation at this time. With Overall, this paper illustrates that DEM techniques can be
the higher spring constant (Fig. 8b) the decay in the oscil- realistically applied to complex mechanical handling devices
lations are much faster and the peak acceleration is much such as bucket elevators to provide insight into the complex
higher (note the change in vertical scale). The motions occur interactions that occur during operation.
over a correspondingly shorter time frame. These very high
accelerations are not anticipated to be realised in physical
testing due to the mass and damping of the belt material, and References
its additional freedom which was unable to be captured in
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3. www.go4b.com/usa/pdf-datasheets/sj-elevator-bucket.pdf
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