DESC:FIELD OF INVENTION
[001] The present invention relates to the field of bucket elevators. Particularly, the present invention relates to a bucket elevator having improved discharge behavior of bulk material, thereby reducing loss of bulk material.
BACKGROUND OF THE INVENTION
[002] Handling of bulk materials is a part of every consumer industry. The bulk materials which are produced must be transported at some point of time or stored. A bucket elevator is a conveyer system comprising of a plurality of buckets and is used to vertically lift or move various bulk materials comprising dry, wet and even mixture of materials. The buckets in the bucket elevator are attached to a rotating belt or a chain and are used to efficiently move the bulk materials between different levels. The buckets scoop up bulk material from a lower level and carry it to a higher level, where it is released or discharged into a discharge chute or another system due to gravitational or centrifugal force. It is designed based on various parameters like height, speed, construction and type of material that needs to be transported.
[003] Modern bucket elevators discharge bulk materials by a mixture of centrifugal and gravimetrical forces which depends on conveying speed. There are other influences for material discharge i.e., bucket shape (dimension and fixation), bulk material (density & grain size) and angle velocity of bucket (speed at circumference). One major limitation of bucket elevators is that they may not be suitable for handling extremely fine bulk materials, as such materials can create dust accumulation in the machinery and pose challenges in terms of spillage and material loss. Furthermore, the size and configuration of the buckets may impact efficiency with certain type of materials. Regular maintenance of the bucket elevators is also crucial for ensuring smooth operation, which requires high upkeep of the elevator system.
[004] There are various prior art documents that highlight bucket elevators and their functioning.
[005] The prior art document, WO2021188090A1 suggests a bucket elevator for bulk materials, containing a head with a drum connected by elevator pipes with a shoe, which houses a second drum, a traction belt placed in the elevator pipes with buckets attached to it. The traction belt buckets are made with enlarged diverging guide elements on the side walls to reduce the number of backspills of the transported material, in addition, in the lower part of the shoe body, paired slots are made for the possibility of transporting the assembled elevator in a vertical position using a forklift, as well as the tensioner of the traction belt is combined with lifting ears, and the adjustment of the drive drum is provided by its fastening on self-aligning bearings, one of which has the ability to vertically real displacement, and the adjusting unit is made in the form of a pressure bolt mounted on a special bracket, and the drive drum is kinematically connected directly to the gearbox axis, and the torque is transmitted through the gearbox lever and bracket, which are flexible in mutually perpendicular planes, and the shoe is equipped with a quick-release hatch and a retractable pallet for quick cleaning of the shoe when changing the type of transported material. The aforementioned prior art comprises traditional and basic elements such as chains/ belts and rims/pulleys, and hence is not efficient. Further, the prior art pertains to modification in traction element by providing diverting guide. The diverting guide can be applied for low capacity or non-abrasive material. However, it does not reduce back fall of all types of bulk materials.
[006] Another prior art document titled “Design and analysis of bucket elevator” suggests a bucket elevator that increases the load carrying capacity of the elevator bucket. Another aim is the relief of strain on the bucket lead edges and the clamping bolts.
[007] However, none of the cited prior art documents provides a cost effective solution for various issues pertaining to improper material discharge at the bucket elevator’s head, which further results in a number of consequences like back fall of materials at the bucket elevator’s head, increased motor current by extra scooping work at bucket elevator’s boot, increased wear and tear, increased noise, dust nuisance, decreased mass flow, worn shaft casings, worn buckets, overpressure in the housing and problems with conveying capacity.
[008] Therefore, a need arises to enhance the material flow at the bucket elevator’s head and incorporate an improved bucket apparatus and also to devise a bucket elevator that guarantees early and efficient material discharge and enables the bulk material to travel straight to the discharge chute.
OBJECTIVES OF THE INVENTION
[009] The primary objective of the present invention is to provide a bucket elevator system to enhance the material flow at bucket elevator’s head.
[0010] Another objective of the present invention is to incorporate an improved bucket apparatus that ensures effective material discharge.
[0011] Another objective of the present invention is to provide a lower bucket fixation point to guarantee early material discharge.
[0012] Yet another objective of the present invention is to enable the bulk material to travel straight towards discharge chute without any material loss.
[0013] Yet another objective of the present invention is to provide plurality of vent holes on bucket surface to prevent bulk material from compacting.
[0014] Yet another objective of the present invention is to achieve proportional discharge of bulk materials.
[0015] Other objectives and advantages of the present invention will become apparent from the following description taken in connection with the accompanying drawings, wherein, by way of illustration and example, the aspects of the present invention are disclosed.

SUMMARY OF THE INVENTION
[0016] The present invention relates to a bucket elevator system (100) for handling bulk materials, comprising a plurality of buckets (102) having a surface with a vent hole pattern; a traction belt (104) configured to attach the buckets (102) at a lower fixation point; at least one motorized pulley and one take-up pulley (106) configured to move the traction belt; a bulk material outlet (108) is configured to receive discharged bulk material from the buckets; a collection box or equipment (110) is configured to collect discharged material; a bulk material feeding unit (112) configured to fill the buckets with bulk material; at least one inspection window (114); and wherein the vent hole pattern at bucket may prevent compaction of the bulk material; wherein the lower fixation point may enable early activation of centrifugal forces for discharging the bulk material.

BRIEF DESCRIPTION OF DRAWINGS
[0017] The present invention will be better understood after reading the following detailed description of the presently preferred aspects thereof with reference to the appended drawings, in which the features, other aspects and advantages of certain exemplary embodiments of the invention will be more apparent from the accompanying drawing in which:
[0018] Figure 1 illustrates the schematic view of bucket elevator system;
[0019] Figure 2 illustrates the (a) top view of bucket; (b) side view of bucket; (c) front view of bucket; (d) back view of bucket.

DETAILED DESCRIPTION OF THE INVENTION

[0020] The following description describes various features and functions of the disclosed apparatus. The illustrative aspects described herein are not meant to be limiting. It may be readily understood that certain aspects of the disclosed apparatus can be arranged and combined in a wide variety of different configurations, all of which are contemplated herein.
[0021] The following description of preferred embodiments of the invention is not intended to limit the invention to these preferred embodiments, but rather to enable any person skilled in the art to make and use this invention.
[0022] These and other features and advantages of the present invention may be incorporated into certain embodiments of the invention and will become more fully apparent from the following description as set forth hereinafter.
[0023] Accordingly, those of ordinary skill in the art will recognize that various changes and modifications of the embodiments described herein can be made without departing from the scope of the invention. In addition, descriptions of well-known functions and constructions are omitted for clarity and conciseness.
[0024] The terms and words used in the following description and claims are not limited to the bibliographical meanings, but, are merely used to enable a clear and consistent understanding of the invention. Accordingly, it should be apparent to those skilled in the art that the following description of exemplary embodiments of the present invention are provided for illustration purpose only and not for the purpose of limiting the invention.
[0025] It is to be understood that the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise.
[0026] It should be emphasized that the term “comprises/comprising” when used in this specification is taken to specify the presence of stated features, integers, steps or components but does not preclude the presence or addition of one or more other features, integers, steps, components or groups thereof.
[0027] The following description describes various features and functions of the disclosed system with reference to the accompanying figures. In the figures, similar symbols identify similar components, unless context dictates otherwise. The illustrative aspects described herein are not meant to be limiting. It may be readily understood that certain aspects of the disclosed system can be arranged and combined in a wide variety of different configurations, all of which have not been contemplated herein.
[0028] Accordingly, the present invention relates to the field of bucket elevators. Particularly, the present invention relates to a bucket elevator having improved discharge behavior of bulk material, thereby reducing loss of bulk material.
[0029] In an embodiment a bucket elevator system (100) for handling bulk materials, comprising: a plurality of buckets (102);a traction belt or chain (104); at least one motorized pulley and one take-up pulley (106); a bulk material outlet (108); a collection box or equipment (110); a bulk material feeding unit (112); and at least one inspection window (114).
[0030] Figure 1 of the present invention illustrates the various components of the system comprising:
[0031] a) A plurality of buckets (102): The plurality of buckets (102) having a surface with a vent hole pattern to prevent bulk material from settling and compacting due to minor vibrations or shaking while transportation as illustrated in Figure 2. The vent hole pattern is incorporated on the front and side walls of the bucket (102). The plurality of vent hole on the surface of the bucket enables the atmospheric forces to act on bulk material and thereby prevent the compaction of bulk material. The vent holes ensures the proper air release caused due to bulk density variances. In an exemplary embodiment the bucket (102) is an AA type of elevator bucket having strengthened rear wall, reinforced corner and edges. In another exemplary embodiment the buckets are deeper and have a lower attachment point to the belt/chain.
[0032] b) A traction belt (104): the traction belt (104) is a flexible material stretched between one motorized pulley and one take-up pulley (106) in the form of loop that attaches a plurality of bucket (102) on its surface. The plurality of buckets (102) is attached with the bucket belt through fasteners. In an exemplary embodiment the fasteners is selected from the group comprising of, such as, but not limited to bolts and nuts.
[0033] c) A motorized pulley (106): the motorized pulley (106) with high-torque motor rotates the bucket belt or chain when power source is supplied. In an exemplary embodiment, one motorized pulley and one take-up pulley (106) are incorporated in the bucket system one at the head section and the other at the boot section.
[0034] d) A bulk material outlet (108): the bulk material outlet (108) is configured to unload the bulk material.
[0035] e) A collection box (110): the collection box (110) collects any discharged material during testing of new bucket designs. In normal operation of the bucket elevator, material is directly conveyed from buckets to the discharge chute and fed to further equipment or systems.
[0036] f) A bulk material feeding unit (112): The bulk material feeding unit (112) is configured to fill the buckets with bulk material. The bulk material is weighed and filled in the buckets by using the bulk material feeding unit (112) during testing of new bucket designs.
[0037] g) An inspection window (114): at least one inspection window (114) is incorporated in the system (100) for inspection of material. In an exemplary embodiment, the window is in the form of laterally arranged viewing flap. The inspection window (114) comprises a laterally arranged viewing flap.
[0038] h) In an exemplary embodiment, a lightening device (116)) is selected from the group of, such as, but not limited to bulb and is configured to illuminate a part of test bucket elevator. In an exemplary embodiment the lightening device (116).
[0039] In an embodiment as show in Figure 1, the bucket (102) is attached to the traction belt (104). The bulk material is filled in the buckets (102) through feed chute. The motorized pulley (106) rotates when power source is supplied and moves the bucket belt in vertically upward direction. The buckets (102) move upward at a particular height and descend in rotational manner. The velocity of bucket depends on elevator sizing and diameter of pulley (106) and can vary based on size of bucket. The working of the system is inspected through windows (114). During the bucket belt movement, the descended bulk material is collected in the bulk material outlet (108) and back fall material is collected in the bottom area of the elevator. The system results in very limited back fall of less than 5%, less sensitivity at wrong adjusted discharge lip and perfect discharge behavior.
[0040] The bucket elevator system (100) enables effective material discharge as material travels to the discharge chute due to multiple factors: 1) Centrifugal force, which depends on speed and material properties; 2) Gravitational force; and 3) The point of material discharge. In an exemplary embodiment, bulk material comprises raw meal, cement and mixture of material.
In another exemplary embodiment, the mounting holes in the buckets are at a comparatively lower position on the rear plate. The buckets are fastened to belts/chains using these mounting holes. The lower bucket fixation point, which is lower positioning of the mounting holes allows for earlier activation of centrifugal forces during operation. The vent hole pattern on the bucket surface helps prevent bulk material from compacting to aid in appropriate discharge.
[0041] In another embodiment, the present invention relates to a method of operating the bucket elevator system (100), comprising steps of:
• filling the buckets (102) with bulk material through the inlet of the bucket elevator boot;
• activating the at least one motorized pulley (106) to move the traction belt (104) vertically upward;
• rotating the pulley on the bucket elevator using the motor connected to the pulley; and
• discharging the bulk material from the buckets (102) into the bulk material outlet (108) due to gravity or centrifugal force or a combination of both.
[0042] In an embodiment, the bucket elevator system may incorporate structural features that facilitate substantially straight travel of bulk material to the outlet. The lower fixation point of the buckets on the traction belt may allow for earlier activation of centrifugal forces as the buckets rotate around the upper pulley. This early activation may propel the bulk material outward at an optimal angle aligned with the outlet. Additionally, the bucket shape and orientation may be configured to direct material flow towards the center of the outlet opening. In some implementations, discharge lip plate may be strategically positioned near the discharge point to help channel the material stream. The spacing and positioning of buckets on the belt may also be optimized to create a more continuous and directed flow of material. Furthermore, the outlet itself may feature a tapered or funnel-like design to help concentrate the material stream as it exits the system. These various elements may work in concert to promote a more direct and efficient transfer of bulk material from the buckets to the outlet, minimizing opportunities for scattering or back-fall.
[0043] In an embodiment the bucket elevator system (100) provides significant advantages:
• The present invention is to provide to enhance the material flow at bucket elevator’s head.
• The present invention is to incorporate an improved bucket apparatus that ensures effective material discharge.
• The present invention is to provide a lower bucket fixation point to guarantee early material discharge.
• The present invention is to provide a system to enable the bulk material to travel straight towards discharge chute without any material loss.
• The present invention is to provide a plurality of vent holes on bucket surface to prevent bulk material from compacting.
• The present invention is to provide a proportional discharge of bulk materials.
• The present invention is to provide a bucket elevator system that limited back fall of less than 5%
[0044] While the present invention has been described with reference to one or more preferred aspects, which aspects have been set forth in considerable detail for the purposes of making a disclosure of the invention, such aspects are merely exemplary and are not intended to be limiting or represent an exhaustive enumeration of all aspects of the invention.
,CLAIMS:WE CLAIM:
1. A bucket elevator system (100) for handling bulk materials, comprising:

a. a plurality of buckets (102), having a surface with a vent hole pattern;
b. a traction belt or chain (104) configured to attach the buckets (102) at a lower fixation point;
c. at least one motorized pulleys and one take-up pulley (106) configured to move the traction belt;
d. a bulk material outlet (108) is configured to receive discharged bulk material from the buckets;
e. a collection box or equipment (110) is configured to collect discharged material;
f. a bulk material feeding unit (112) configured to fill the buckets with bulk material; and
g. at least one inspection window (114);
wherein,
• the vent hole pattern may prevent compaction of the bulk material;
• the lower fixation point may enable early activation of centrifugal forces for discharging the bulk material;
• the system enabling the bulk material to travel substantially straight to the bulk material outlet with limited back-fall.

2. The bucket elevator system (100) as claimed in claim 1, wherein the vent hole pattern is incorporated on front and side walls of each bucket.

3. The bucket elevator system (100) as claimed in claim 1, wherein each bucket (102) having a strengthened rear wall, reinforced corners

4. The bucket elevator system (100) as claimed in claim 1, wherein the plurality of buckets (102) are attached to the traction belt (104) through fasteners selected from the group comprising of bolts and nuts .

5. The bucket elevator system (100) as claimed in claim 6, wherein the inspection window (114) comprises a laterally arranged viewing flap.

6. A method of operating the bucket elevator system (100) as claimed in claim 1, comprising:
• filling the buckets (102) with bulk material;
• activating the at least one motorized pulley and one take-up pulley (106) to move the traction belt (104) vertically upward;
• discharging the bulk material from the buckets (102) into the bulk material outlet (108); and
• collecting any back-fall material in the collection box (110).