The bucket elevator is a key conveying equipment in the quartz sand
production line, responsible for vertically conveying crushed and screened
quartz sand to the silo (with a rated conveying capacity of ≥ 50t/h and a
failure rate of ≤ 1 time/week), which directly affects the continuous operation
efficiency of the production line. If there is a decrease in conveying capacity
(below 30% of the rated value) and frequent chain jamming (more than 3 times a
week), it will lead to material accumulation in front-end equipment and material
breakage in back-end processes. Combining the characteristics of high density
(2.65g/cm ³) and strong wear resistance of quartz sand, a three-step
investigation method is summarized to quickly restore the conveying
performance.
Step 1: Optimize the traction components and transmission system - core power
guarantee transmission efficiency
Chain/belt wear and insufficient transmission accuracy are the main causes of
decreased conveying capacity and jamming.
Poor adaptability or wear of traction components: ordinary plate type chains
are used, and when the chain links wear more than 0.5mm, the meshing clearance
increases, causing jamming due to running vibration; The rubber belt is worn by
quartz sand, and the surface groove depth exceeds 2mm. The hopper is fixed
loosely and prone to tilting and material leakage. Replace the high-strength
roller chain for quartz sand (material 40Cr, surface carburizing treatment), and
control the wear of the chain link to ≤ 0.2mm; if it is a belt type, use
wear-resistant rubber belt (covering rubber thickness ≥ 15mm), and regularly
check the tightening torque of the hopper bolts (maintain 80-100N · m).
Abnormal transmission sprocket or speed deviation: The sprocket tooth surface
wears dull (the thickness of the tooth tip decreases by 1/3), poor meshing with
the chain, and easy occurrence of chain jumping; The motor speed fluctuates by
more than 5 r/min, the conveying frequency is unstable, and the conveying volume
fluctuates between high and low; The lubricating oil of the reducer is aging,
the transmission resistance increases, and the speed implicitly decays. Replace
the wear-resistant sprocket (tooth surface hardness HRC ≥ 55), and calibrate the
coaxiality of the sprocket during installation (deviation ≤ 0.3mm); Calibrate
the motor speed with a tachometer and stabilize it at the rated value (usually
25-30r/min) through a frequency converter; Replace the dedicated gear oil for
the reducer, ensuring that the oil level is at 2/3 of the scale line.
Step 2: Calibrate hopper design and loading parameters - Material adaptation
to enhance feeding capacity
Improper hopper type, loading method, and spacing can exacerbate the
attenuation of conveying capacity.
Mismatching or wear of hopper selection: shallow hopper is selected, with a
quartz sand loading coefficient of only 60%, and it is easy to scatter
materials; The inner wall of the hopper has worn out by more than 3mm, resulting
in a decrease in volume and a reduction in the amount of material loaded in a
single operation; The spacing between hoppers is too large (over 300mm), and the
number of hoppers lifted per unit time is insufficient. Replace the deep hopper
or non formatted hopper, and increase the loading factor to over 85%; Choose
high manganese steel material for the bucket, and install wear-resistant lining
plates on the inner wall; Adjust the spacing between the hoppers to 200-250mm to
ensure that the hoppers are fully loaded in the bottom loading area.
Abnormal loading method or amount: the gap between the feeding port and the
hopper exceeds 50mm, and the quartz sand spillage rate exceeds 15%; The feed
rate exceeds the rated value by 20%, and the overload of the hopper leads to an
increase in the running resistance of the chain, and even jamming. Install a
feeding guide plate to reduce the gap between the feeding port and the hopper to
20-30mm; use an electronic belt scale to control the feeding amount and maintain
it at 80% -90% of the rated value; Install an overflow plate at the feed inlet
to prevent excessive material from entering the barrel.
Step 3: Optimize the tensioning system and barrel protection - avoid the risk
of jamming at the source
Insufficient tension, accumulation of material in the barrel, and guiding
deviation can affect operational stability.
Failure or improper parameters of the tensioning system: insufficient stroke
of the heavy hammer tensioning device (less than 1/2 of the design value),
insufficient chain tension (less than 15kN), and jumping and jamming during
operation; Spring type tensioner spring fatigue, elastic deformation exceeding
3mm, and large fluctuations in tension force. Adjust the weight of the heavy
hammer to ensure that the tension stroke is within the range of 1/2-2/3 of the
design value, and the chain tension is stable at 18-22kN; replace the fatigue
spring and regularly check the operating status of the tensioner to avoid
jamming and failure.
Accumulation or deviation of material in the machine barrel: The thickness of
material accumulation at the bottom of the machine barrel exceeds 100mm, and the
material accumulation is scraped and stuck during the operation of the hopper;
The guide plate is worn or offset, and the gap with the chain/hopper is ≤ 5mm,
which is prone to friction and jamming. Clean the accumulated material at the
bottom of the barrel every week, and install a polyurethane wear-resistant
lining plate (thickness 8-10mm) on the inner wall of the barrel to reduce
material adhesion; Calibrate the position of the guide plate to ensure a gap of
8-12mm with the chain and avoid frictional interference.
Daily maintenance should pay attention to: checking the tension of the chain,
the integrity of the hopper, and any abnormal noises from the machine barrel
every day; Calibrate the motor speed and clean the accumulated material in the
barrel every week; Monthly inspection of sprocket wear and replacement of
gearbox lubricating oil; Adjust the tensioning device quarterly and replace the
worn guide plate. By taking the above measures, the conveying capacity can be
restored to over 90% of the rated value, and the jamming failure rate can be
reduced to less than once per month, ensuring the continuous operation of the
production line. If there are still problems, it is recommended to contact the
manufacturer to optimize the hopper structure and tensioning system parameters,
and match the quartz sand conveying conditions.