ADDIS ABABA SCIENCE AND TECHNOLOGY

UNIVERSITY

COLLEGE OF ELECTRICAL AND MECHANICAL ENGINEERING

DEPARTEMENT OF ELECTROMECHANICAL ENGINERRING

MATERIAL HANDLING EQUIPMENT

GROUP ASSIGNMENT

SECTION E

NAME ID NO

SAMUEL ALATO ETS 1031/10

ROBERA TAREKEGN ETS 1015/10

NAOL TAREKEGN ETS 0912/10

SURAFEL DENEKE ETS 1108/10

TIBEBE GIWERGIS DEREJE ETS 1164/10

SUBMITTED TO : Mr. ANNUAR.M

FEB 14, 2022

ABSTRACT

Bucket elevators are used for transport of bulk, dry, wet and even liquid materials. It is designed for
various parameters like height, speed and constructive based on the type of material to be transported. The
main aim of the project is to increase the load carrying capacity of the elevator bucket. Another aim is the
relief of strain on the bucket lead edges and the clamping bolts. Bucket elevators always display problems
when under harsh operating conditions, or build up (in the case of sticky bulk materials) are encountered.
In order to avoid these problems high capacity bucket is designed to carry higher loads. This can be
achieved from finite element approach. 3D model of Bucket Elevator is modeled using CATIA and
analyzed using ANSYS. From the results topology design will be suggested and re-iteration will be
carried to prove it safe. Results validated with the experimental results.

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 CONTENT
ABSTRACT............................................................................................................... 1
CHAPTER 1.............................................................................................................. 3
INTRODUCTION.....................................................................................................3
CHAPTER 2.............................................................................................................. 5
LITERATURE REVIEW........................................................................................ 5
2.1 BUCKET CONVEYOR..................................................................................... 6
CHAPTER 3.............................................................................................................. 7
3.1 WORKING PRINCIPLE...................................................................................7
3.1.1 BUCKET CONVEYOR ADVANTAGES..................................................8
3.2 ATTACHMENTS OF BUCKETS................................................................. 8
3.2.1 CHAIN........................................................................................................... 8
3.2.2 BELTS............................................................................................................8
3.3 PROBLEM STATEMENT................................................................................ 9
CHAPTER 4........................................................................................................... 10
SYSTEMATIC METHODOLOGY FOR PROJECT........................................ 10
4.1 ANALYTICAL DESIGN................................................................................. 10
4.2 DESIGN CALCULATION...........................................................................11
4.3 ANALYSIS..................................................................................................... 18
4.4 BOUNDARY CONDITION......................................................................... 19
4.5 TOTAL DEFORMATION........................................................................... 20
4.6 EXPERIMENTAL TESTING......................................................................21
4.7 TEST PLOTS................................................................................................. 22
4.8 APPLICATION............................................................................................. 23
CHAPTER 5............................................................................................................ 25
RESULTS AND DISCUSSIONS...........................................................................25
CHAPTER 6............................................................................................................ 26
CONCLUSION........................................................................................................26

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 CHAPTER 1

INTRODUCTION

Material Handling is a part of consumer industry. For every product which is produced has
to be transported at some point of time or stored at storage. So what is Material Handling?
Material handling is defined as the storage and movement of materials. The material handling
industry is efficient as the material handling equipment. Material Handling Solutions provides
the best material handling equipment available for moving and storing materials affectively and
quickly. To move the material from specific points conveyors are used which also divided into
based on the type of load handled. Screw conveyor and belt bucket conveyor are the basic
example of the conveyor.
A conveyor system is used for identification and separation. The conveyor system consists
of the roller, flat belt and chute segments which is having variable [Link] bucket elevators
are used to move materials upwards directions at particular height. The elevators use an endless
chain/belt which is attached with the buckets. The bulk material is divided based on an inlet
hopper where the buckets takes the material and convey it up and over the head sprocket.
Thereafter, the buckets take the material out via a discharge spout as shown in the [Link]
buckets are returned down to the tail sprocket at the bottom. The bucket elevator consists of
buckets to contain the material, chain or belt drive to carry the buckets and transmit the pull. In
addition, it also has electrical motor to drive the chain or belt, loading and discharge spout for
loading the buckets at the boot and receiving the discharged material at the head respectively.
Tensioning device is also installed for maintaining the chain/belt tension. All these accessories
are enclosed and protected in a casing.

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4
 CHAPTER 2

LITERATURE REVIEW

A bucket elevator can elevate a variety of bulk materials from light to heavy and from
fine to large lumps.

A centrifugal discharge elevator may be vertical or inclined. Vertical elevators depend

entirely on centrifugal force to get the material into the discharge chute, and so must be run at a
relatively high speed. Inclined elevators with buckets spaced apart or set close together may have
the discharge chute set partly under the head pulley. Since they do not depend entirely on
centrifugal force to put the material into the chute, their speed may be slower.

Nearly all centrifugal discharge elevators have spaced buckets with rounded bottoms. They pick
up their load from a boot, a pit, or a pile of material at the foot pulley.

The buckets can be also triangular in cross section and set close together on the belt with
little or no clearance between them. This is a continuous bucket elevator. Its main use is to carry
difficult materials[clarification needed] at slow speed.

Early bucket elevators used a flat chain with small, steel buckets attached every few
inches. While some elevators are still manufactured with a chain and steel buckets, most current
bucket elevators use a rubber belt with plastic buckets. Pulleys several feet in diameter are used
at the top and bottom. The top pulley is driven by an electric motor.

The bucket elevator is the enabling technology that permitted the construction of grain
elevators. A diverter at the top of the elevator allows the grain to be sent to the chosen bin.

A similar device with flat steps is occasionally used as an elevator for humans, e.g. for
employees in parking garages.

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2.1 BUCKET CONVEYOR

A bucket conveyor is used to move the various bulk materials in upwards direction.
Vertical elevators depend on centrifugal force so that materials will flow in to the discharge
chute and runs at high speed. Centrifugal bucket elevator is having the spaced bucked with
rounded bottoms. These buckets are mounted on conveyor either close to each other or mounted
apart. Bucket conveyor is consists of flat chain on which small bucket is bolted. Most of the
times rubber belt with plastic bucket is also used. Pulleys are used on top and bottom with
specified diameter. The pulley is driven by an electric motor. The conveyor allows the materials
sent to the chosen bin.

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 CHAPTER 3

3.1 WORKING PRINCIPLE

The recycling bucket of Bucket Conveyor scoops the materials up form the storage bin,
conveyor to the top with the conveyor belt or chain, flip down after by pass the top wheel, and
poured material into the receiving groove. Belt driving The belt normally is rubber belt) of
Bucket Conveyor is installed at top and down transmission drum or the top and down idler drum.
Chain driving (generally are two parallel transmission chain) is installed on the Bucket Conveyor,
at the top and down, there are a pair of drive sprocket. At down and top, there is a pair of idler
sprocket. Normally the bucket conveyor is with shell to prevent the dust inside the bucket and
also dust generated during delivery.
These elevators are utilized to transfer the granular material vertically. The fundamental
parts of the gadget are an endless belt or chain as a footing component to which are connected a
progression of conveying buckets
A solitary or twofold packaging, which serves to encase or incompletely encase the moving
buckets. Ahead at the upper finish of the elevator which incorporates a belt pulley or chain wheel
to turn the footing component and an appropriate release chute…
A boot at the lower end again incorporates a belt pulley or chain wheel, a tension gadget,
and methods for taking care of the material to be passed on to guarantee ideal filling.
The hopper scoop up the material from the storage below, lifting it along the conveyor belt or
chain to the top, bypassing the top wheel and turning it down, and the bucket elevator empties
the material into the receiving tank. The belt of a bucket elevator with a belt conveyor is usually
made of rubber belts, mounted on or below the drive drum and on the up and down rollers. A
chain driven bucket elevator is usually equipped with two parallel transmission chains, with or
without a pair of drive sprockets on or below, and a pair of modified sprockets on or below.
Bucket elevator generally equipped with shell, in order to prevent bucket lifting machine dust
flying.

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3.1.1 BUCKET CONVEYOR ADVANTAGES
1, drive power is small, the use of inflow feeding, induction discharge, large capacity hopper
intensive layout. In material lifting, almost no return and excavation phenomenon, therefore, less
power.
2, a wide range of lifting, this type of hoist on the type of materials, characteristics of the
requirements of less, not only can enhance the general powder, small granular materials, but also
to enhance the grinding of larger materials. Good sealing, less environmental pollution.
3 、 good operation reliability, advanced design principle and processing method ensure the
reliability of the whole machine, and the trouble free time is more than 20 thousand hours. The
lifting height is high. The hoist runs smoothly, so it can achieve a higher lifting height.
4. The service life is long, the feeding of the hoist adopts the inflow type, and the bucket is not
needed to dig the material. There is little extrusion and collision between the materials. This
machine in the design to ensure the materials in the feeding and unloading is less scattered,
reduces the mechanical wear.

3.2 ATTACHMENTS OF BUCKETS

3.2.1 CHAIN

With the used of hex head bolts, bucket is attached to the chain with lock washers. As from the
figure 2, bolt head is inside the bucket.

3.2.2 BELTS

To attached buckets to the belt, Norway bolt or oval head type bolt is used. As from figure 2,
the flat of oval head is placed on the pulley side of the belt with the use of a lock washer and nut.
Pliable washer is used between the belt and bucket.

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3.3 PROBLEM STATEMENT

Bucket elevators are widely used equipment in mechanical industry. Satisfactory level of
materials we are using till now for buckets are not sufficient so it is always advisable to find the
new material. Vibration can cause failure of structure

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 CHAPTER 4

SYSTEMATIC METHODOLOGY FOR PROJECT

 To study about the bucket including the type of failure.

 To study the various work on this subject including reading previous research papers on this
subject.
 To design the bucket for the particular application by using the analytical method.
 Modeling the geometry in the CAD software.
 Pre-processing of geometry in the Analysis software.
 Processing the results.
 Post-processing the result including getting various results.
 Experimentation of the bucket.
 Validation of the results.

4.1 ANALYTICAL DESIGN

To handle varieties of dry and wet materials, design and manufacturing criteria is very
important which is handled by Martin Conveyor Designs In this project, we are selecting
Centrifugal Discharge Chain elevator for design and analysis of bucket. For design of bucket we
are referring Martin catalogue, this catalogue is designed to make a preliminary selection of a
bucket elevator and bucket size.
Malleable iron buckets generally used for free flowing materials. Centrifugal Discharge buckets
can be mounted on chain or belt.

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4.2 DESIGN CALCULATION

Volume of a semi-circular

Volume of rectangle

Volume of rectangle

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Total volume of elevator bucket

Particle density = 0.8g/cc = 800

m= 0.8Kg
Total mass of coir pith collected in bucket 0.8 Kg
Force apply on bucket is mass= 0.8 x 9.8
= 7.84 N

Determining Horse Power

In order to accurately determine the power requirements of a bucket elevator, the internal forces
acting on the unit must first be understood. Although there are many components in the bucket
elevator, only the upward movement of the conveyed product needs to be considered. This is
because the weight of the belt and buckets are identically balanced on both sides of the head
shaft. Only the internal friction caused by the movement of these components needs to be
considered when calculating the HP requirements.

There are many variations of Horse Power (HP) calculations found in historical and individual
manufacturer’s literature. The formulas below are used to determine the power requirements of
a bucket elevator throughout the industry. Although references are made to belt and pulley style
bucket elevators, the principles of design contained in this chapter apply to sprocket and chain
style bucket elevators, as well.

A basic power calculation is the measure of force over a distance per time period.

���
�=
�
Where: P = Power
F = Force
D = Distance
T = Time

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In a bucket elevator the power requirement can be directly calculated using this formula.

���
�= +�
�

Where:
P = Power to convey the product
W = Weight of material being lifted
H = Lift Height
T = Time
C = HP required to overcome the friction in the system.

The frictional losses in the system come primarily from the following factors:
 Drive Inefficiencies
 Belt slip on the head pulley
 Chain slip on sprockets
 Bearing friction
 Digging by elevator buckets in the boot

G � [DH + d � L�� ]
P = � C���
��� ��
��� ���
60 � 33000
ℎ� ��

Where:
P = Power (HP)
G = Gravimetric Rate (lbs per hour)
DH = Discharge Height (ft)
d = Diameter of tail pulley (ft)
Leq = Length equivalency factor (ft)
Ceff = Efficiency factor (dimensionless)

Using the above formula the following example can be solved for horse power.

A Customer would like to convey 100,000 lbs per hour of sand to a height of 105 feet.
Determine the required HP.
Rate (G) = 100,000 (lbs per hour)
Discharge Height (DH) = 105 (ft)
Tail Pulley Diameter = 2 (ft)
Length equivalency factor (Leq)= 7 (Assumed)
Efficiency factor (Ceff)= 1.15 (Assumed)

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 ���
100,000 � [105 �� + 2 �� � 7 ]
�= ℎ� � 1.15 = 6.91 ��
��� ��
��� ���
60 � 33000
ℎ� ��

Headshaft Design for Stress

As discussed above the design of the headshaft for a bucket elevator is one of the most critical
calculations for a proper design. The first criteria to evaluate is the maximum stress in the shaft.
The formula below is a conservative approach to shaft design and a generous safety factor should
be utilized. In addition, the formula below does not account for a large drive being overhung
outside of the bearing centerlines. Large overhung loads will need to be evaluated in a method
separate from the information provided in this guide.
3 2
32 � �� � 2 3 �
�= �
� ��
+ 4
� ��

Equation 4.04 – Minimum Shaft Diameter

Where:
D = Minimum Shaft Diameter (in)
FS = Factor of Safety
M = Bending Moment (In-lbf)
Sf = Corrected Shaft Fatigue Limit (lbf per square inch)
T = Torsional Moment (lbf-in)
Sy = Maximum Shear Stress (lbf per square inch)

The corrected shaft fatigue limit is adjusted for the conditions of the material used to make the
shaft utilizing the following factors

�� = �� � �� � �� � �� � �� � �� � �� � �� � �∗�
Equation 4.05 – Corrected Shaft Fatigue Limit
Where:
Ka = Surface Factor (0.8 for machined shafts)
Kb = Size Factor (D-0.19)
Kc = Reliability Factor (0.897)
Kd = Temperature Factor (1.0 for -70ºF – 400ºF)
Ke = Duty Cycle Factor (1.0, provided stresses do not exceed Sf)
Kf = Fatigue Stress Concentration Factor:

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Steel Profiled Keyway Sled Runner Keyway
Annealed (Less than 200 BHN) 0.63 0.77
Quenched and Drawn (Over 200 0.50 0.63
BHN)
(The steals listed below can be considered to be below 200 BHN)

Kg = Misc. Factor (1.0 for normal conveyor service)

Steel Sf* = Endurance Limit (PSI) Sy = Yield Strength (PSI)

SAE 1018 29,000 32,000
SAE 1045 41,000 45,000
SAE 4140 47,500 60,500
(Annealed)
(Sf* = 0.5 x tabulated ultimate tensile strength)

The bending moment (M) is the force excreted on the shaft by the head pulley at the locations
R/2 shown in figure 4.01 below.

�
�= ��
2

Where:
M = Moment (in-lbf)
R = Full load directed downward on headshaft (lbs)
A = Distance between the pulley bushing and the headshaft bearing center (in)

To solve this formula, it is necessary to determine all of the loads acting on the headshaft (R) at
the pulley bushing locations. Usually the belt tension is calculated from three components: T1,
T2, and T3. T1 represents the tension due to the weight of the product being elevated. T2
represents the weight of the up side belt and buckets. T3 represents the slack side tension

15
necessary to prevent belt slippage against the head pulley. The only other load to be considered
is the weight of the head pulley itself.
The formula for headshaft loading at the pulley bushings can be written:
� = �1 + �2 + �3 + ��
Where:
R = Full load directed downward on headshaft (lbs)
T1 = Weight of material being lifted (lbs)
T2 = Weight of up side belt and buckets (lbs)
T3 = Slack side tension (lbs)
PW = Weight of the head pulley (lbs)

The belt tension component due to the weight of material being elevated, T1, can be written:

� � ��
�1 =
��� ��
��� ���
60 � 33000
ℎ� ��

Where:
T1 = Weight of material being lifted (lbs)
G = Gravimetric Flow Rate (lbs per hour)
DH = Discharge Height (ft)

T2 represents the weight of the up side belt and buckets. Note that we are not concerned with the
weight of the down side belt and buckets since they are subsumed by T3. T2 can be written as:

��
��� 12 � ��
��
�2 = + �� � �� � ���
��
Where:
T2 = Weight of Up Side Belt and Buckets (lbs)
DH = Discharge Height (ft)
bw = Weight per bucket including hardware (lbs)
bs = Bucket Spacing (in)
BW = Belt Width (in)
PIW = Weight of Belting (lbs per inch width per linear foot)

T3 represents the minimum tension required to prevent belt slippage against the head pulley.
Special consideration should be taken for take-ups which will exert force in addition to that
calculated in formula 4.14. The K factors were empirically determined some time ago and their
source is unknown. They are commonly used and range from 0.5 to 0.9. T3 can be written as:

�3 = �2 + �1 � �

Where:
T3 = Slack Side Tension (lbs)

16
T2 = Weight of Up Side Belt and Buckets (lbs)
T1 = Product Weight in Up Side buckets (lbs)
K = Take-up Tension Factor

The Torsional Moment (T) is the force excreted on the headshaft by the drive and is defined as:

�� � 63025
�=
���
Where:
T = Torsional Moment (Lbf-in)
HP = Horse Power of the Motor
RPM = Revolutions per Minute of the shaft
The shaft slope at the pulley bushings can be determined from the following formula.

�� � − 2�
����� = tan � = = 0.0015 ��/��
4��
Where:
� = Angle Shaft Deflection
R = Full load directed downward on headshaft (lbs)
A = Distance between the pulley bushing and the headshaft bearing center (in)
B = Distance between headshaft bearing centers (in)
E = Modulus of Elasticity of the headshaft material (psi)
I = Moment of inertia of shaft cross-section (in4)

Using equation 4.11 we can insert our known variables and solve for minimum headshaft
diameter, D, which satisfies the CEMA shaft slope criteria.

Slope (�) = .0015 (in/in)

Modulus of Elasticity (E) = 30,000,000(psi)
�
Moment of Inertia = � = 64 �^4 (in^4)

4 �� � − 2�
�=
2812.5

3 32 � �� �
�� = �
� ��

17
Where:
DB = Minimum Bootshaft Shaft Diameter (in)
FS = Factor of Safety
M = Bending Moment (In-lbf)
Sf = Corrected Shaft Fatigue Limit (lbf per square inch)

Formula 4.6 for the bending moment is utilized in the above formula, however the resultant load
(R) on the bootshaft is expressed as:

�� = �1 � � − ��
Equation 4.14 – Bootshaft loading formula
Where:
Rb = Bootshaft Load (lbs)
T1 = Product Weight in Up Side buckets (lbs)
K = Take-up Tension Factor

In general, the loads imposed on the bootshaft are very low when compared to the headshaft.
Special consideration should be taken for take-ups which will exert force in addition to that
calculated in formula 4.14. Most manufacturers will us a simple rule for the bootshaft diameter
to be some fraction of the diameter of the headshaft.

4.3 ANALYSIS

The FEM is mathematical approach to solve the engineering application and Physics problems.
This method is used to solve Heat Transfer analysis, Structural analysis problems. The method
gives approximate values at discrete number of points. From this method we can calculate the
Stress and Strain at various part of the model.

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4.4 BOUNDARY CONDITION

A boundary condition for the model is set a load at particular point to define the factors like
displacements and stress. These applied to points, surfaces and edges. Before applying the
Boundary condition we need to constraint the model first. Over and under constraints gives an
inaccurate results.

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4.5 TOTAL DEFORMATION

The total deformation & directional deformation are general terms in finite element methods
irrespective of software being used.

Total Deformation of Steel Bucket Total Deformation of Epoxy Bucket

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 Equivalent Stress of Steel Bucket Equivalent stress of Epoxy Bucket

4.6 EXPERIMENTAL TESTING

A universal testing machine (UTM) is used to test tensile strength and compressive strength of
material. Below is the specification of the UTM.
Specification:
 High Speed Latest Micro controller based Technology.
 20000 Load Counts in one Range, Load Resolution = Machine
 Capacity / 20000 Optional On board Extensometer facility with 1-micron resolution & up to
20 mm travel. 20 data set storage ( 00 to 19) 75 Results Storage ( Related to one data set)
Data Entry & Parameter selection through Keyboard Non Volatile memory for Result & test
data storage.
 All Stored Results & Last test complete data with Graph will be available.
 Result & Graph printout, Certificate, Batch & Statistics Printout including Standard
deviation.
 kN / kg unit selection for Displayed Load & Results.
 On Board Overload Relay for Load Safety & Encoder Over, travel safety.
 Accurate 2 point Digital Calibration from Panel & PC Software.
 RS232c serial interface for PC connection with variety of latest Windows based software for
data logging & analysis.
 Real time Online Graph on PC.

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 Once PC connected this becomes complete PC controlled system, with all Displays & Key
functions on PC screen.

4.7 TEST PLOTS

Load vs. Deformation plot for Steel Bucket Load vs. Deformation plot for Epoxy Bucket

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4.8 APPLICATION

 Bucket conveyors are used for vertical transportation of bulk and small grain size
materials.

Bucket Conveyor

 For the biomass industry, continuous bucket elevators are not typically desired, but
they can be effective in the back end of a process, with centrifugal bucket elevators
handling the front end.
 For the cement industry, continuous bucket elevators are ideal for handling highly
abrasive material such as clinker. Centrifugal bucket elevators are ideal for handling
less-abrasive material such as finished cement.
 For the glass industry, continuous bucket elevators are better suited to handling
abrasive material with less degradation, so centrifugal bucket elevators are not
typically desired.

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 For the minerals and mining industry, continuous bucket elevators are ideal for
handling highly abrasive, inconsistently sized, friable material. Centrifugal bucket
elevators are ideal for handling material with the opposite characteristics.
 For ports and terminals, continuous bucket elevators are not typically desired, as
centrifugal bucket elevators are better suited for high speeds and handling high
volumes of less-abrasive, free-flowing material.
 For the potash and fertilizer industry, continuous bucket elevators are best for
operations that produce granular material. Centrifugal bucket elevators are best for
operations that produce non-granular material.
 For the power industry, continuous bucket elevators are ideal for higher volumes of
abrasive material such as ash or limestone. Centrifugal bucket elevators are ideal for
handling low volumes of non-abrasive material such as fuel.
 For the pulp and paper industry, continuous bucket elevators are recommended for
handling higher volumes of abrasive material such as wood waste or ash on the back
end of a process. Centrifugal bucket elevators are recommended for handling lower
volumes of non-abrasive material such as fuel on the front end of a process

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 CHAPTER 5

RESULTS AND DISCUSSIONS

Bucket elevator was studied thoroughly. Design was based on the application and Bucket
manufacturer catalogue is mentioned. 3D model is drawn in CATIA V5. The Analysis
was carried out with the help of ANSYS software.

From the analysis results, it is clear that the strength of the epoxy bucket is more than that of the
original material of the bucket. From the UTM testing, Load carrying capacity for both the
bucket is carried out. Steel bucket is having load carrying capacity up to 10 kg and Epoxy bucket
is sustain up to 6 kg.

Weight Reduction = (Existing - Optimized) / Existing

= (0.624 – 0.147)/0.624
= 76.4 %

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 CHAPTER 6

CONCLUSION

 Bucket elevator was studied thoroughly. Design was based on the application and Bucket
manufacturer catalogue is mentioned. 3D model is drawn in CATIA V5. The Analysis was
carried out with the help of ANSYS software.
 From the analysis results, it is clear that the strength of the epoxy bucket is more than that of
the original material of the bucket.
 From static analysis, we get weight of each bucket steel, epoxy is 624g and 147g
respectively that conclude that weight of bucket decrease due to use of glass fibre bucket
hence overall weight of bucket elevator decreases.
 From UTM testing we get reading maximum load carrying capacity of bucket, steel bucket
sustain 10kg load and epoxy bucket sustain 6 kg load hence it conclude that design bucket is
safe for coir pith application.

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