Bucket elevator drawing high power

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Discussion Overview

The discussion centers around the issue of a bucket elevator drawing an unusually high current when loaded, particularly during startup. Participants explore potential causes for this phenomenon, considering mechanical and operational factors related to the elevator's performance.

Discussion Character

  • Exploratory, Technical explanation, Debate/contested

Main Points Raised

  • One participant notes that the bucket elevator draws high current during startup and stabilizes at a lower power when unloaded, but experiences a significant increase in power draw when loaded.
  • Another participant suggests that various mechanical failures, such as motor bearing damage or gearbox lubrication failure, could contribute to the increased load on the motor.
  • Concerns are raised about whether the deformed buckets could impact the motor load, with some participants questioning the relationship between bucket condition and motor performance.
  • There is speculation about the possibility of external mechanical drag or wear in the motor as potential causes for the high loading on the motor.
  • Participants emphasize the need to systematically check various components of the elevator to identify the source of the problem.

Areas of Agreement / Disagreement

Participants express multiple competing views regarding the causes of the high current draw, with no consensus reached on a single explanation. Various mechanical issues are proposed, but the discussion remains unresolved.

Contextual Notes

Limitations include the lack of specific details about the motor's condition and operational history, as well as the absence of definitive evidence linking the deformed buckets to the motor's performance.

Who May Find This Useful

Individuals involved in mechanical engineering, maintenance of conveyor systems, or those troubleshooting similar issues with bucket elevators may find this discussion relevant.

oriehi
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A bucket elevator for conveying solid material (cement mill feed of 30mm~2.5mm) draws an abnormally high current when loaded. some buckets where discovered deformed. The deformed buckets where changed, but the elevator still took high kilowatt on start up. Please what could be the cause.
 
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Welcome to PF;
Lots of things could be doing that - maybe the motor is a bit broken?

It's not clear why you'd expect a deformed bucket to change the load on the motor.
Is the higher than spec current drawn only at the startup, and then it settles down, or is it like that all the time it's running? (Or very high at startup but also higher than spec while running?)
 
The bucket normally draws high load on start up, but stabilizes in few seconds on normal operations with no load (ie about 12kw). but when loaded, the power drawn goes as high as 120kw, as against about 80kw, on normal operating conditions.
We suspected restrictions, but on inspection no restriction was discovered.
 
Some thoughts:
  • motor bearing damage or failure
  • motor winding damage or failure from overheating
  • gearbox bearing damage or failure
  • gearbox lubrication failure
  • bent or damage chain links
  • carrier shaft bearing damage or failure
  • bent or damaged carrier shafts
  • material change (is heavier per unit volume)

The increased current you get is due to an increased load. It could be an increase in torque from many causes.
 
Yeah, that's how I was imagining things ... and I also imagine that something gumming up the works is the most common cause for unusually high loading on the motor.

In the absence of external mechanical drag, you have to suspect the motor is wearing out.
What tygerdawg said ... you just have to work through a checklist.
 
Thanks a lot guys, we'll check it out
 

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