Dredge Bucket Wheel Upgrade

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Dredge Bucket Wheel Upgrade

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Overview

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Tronox were planning to upgrade their dredge power by increasing the cutting torque at the bucket wheel by 33% and the swing winch rope pull by 40%. The client was concerned about the ability of the original wheel design to handle this significant increase in load.

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What we did

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Metis D&E carried out Finite Element Analysis on the bucket wheel in multiple scenarios.

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STEP 1

The first step was to analyse the original design in both the standard and increased torque conditions, then compare the results and identify areas of the wheel structure which required strengthening. The analysis was also conducted using reduced material thicknesses, simulating the effect of abrasive wear.[/vc_column_text][/vc_column_inner][vc_column_inner width=”1/4″][/vc_column_inner][/vc_row_inner][vc_single_image image=”451″ img_size=”full” alignment=”center”][vc_row_inner][vc_column_inner width=”1/4″][/vc_column_inner][vc_column_inner width=”1/2″][vc_column_text css=”.vc_custom_1549876004596{border-top-width: 1px !important;border-bottom-width: 1px !important;padding-top: 10px !important;padding-bottom: 15px !important;border-top-color: #d6d6d6 !important;border-top-style: solid !important;border-bottom-color: #d6d6d6 !important;border-bottom-style: solid !important;}”]

STEP 2

Next, Metis D&E has conducted a series of analyses to determine the optimum reinforcement package which would allow the stress results and Factor of Safety values to reach acceptable levels in the areas of concern. Our focus was to determine reinforcement solutions which would be practical to implement and would achieve the desired strengthening without compromising the weight and cutting capacity of the wheel.

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Results

[/vc_column_text][/vc_column][/vc_row][vc_row][vc_column width=”1/2″][interactive_banner banner_title=”Current Bucket” banner_desc=”Metis identified 3 main areas of concern where the maximum stress values were exceeding acceptable levels and premature failure was predicted:

Weld Bucket/Hub
Weld Bucket/Ring
Stabiliser Ring” banner_image=”id^453|url^https://www.metisde.com.au/wp-content/uploads/2018/05/Current-Bucket.png|caption^null|alt^null|title^Current Bucket|description^null” banner_height=”ult-banner-block-custom-height” banner_height_val=”465″ banner_overlay_bg_color=”rgba(0,0,0,0.7)” banner_desc_font_size=”desktop:18px;tablet:18px;tablet_portrait:18px;mobile_landscape:18px;mobile:18px;” banner_title_font_size=”desktop:20px;tablet:20px;tablet_portrait:20px;mobile_landscape:20px;mobile:20px;”][/vc_column][vc_column width=”1/2″][interactive_banner banner_title=”New Bucket” banner_desc=”Our solution involved:

Increasing the radius of the clearance profile for the trailing bucket edge;
Lengthening the bucket-hub connection;
Extending the bucket stabiliser ring connection so that all buckets are connected and welded to each other;
Use of a double bevel bucket profile.” banner_image=”id^454|url^https://www.metisde.com.au/wp-content/uploads/2018/05/New-Bucket.png|caption^null|alt^null|title^New Bucket|description^null” banner_height=”ult-banner-block-custom-height” banner_height_val=”465″ banner_overlay_bg_color=”rgba(0,0,0,0.7)” banner_title_font_size=”desktop:20px;tablet:20px;tablet_portrait:20px;mobile_landscape:20px;mobile:20px;” banner_desc_font_size=”desktop:18px;tablet:18px;tablet_portrait:18px;mobile_landscape:18px;mobile:18px;”][/vc_column][/vc_row][vc_row css=”.vc_custom_1549871912454{margin-top: 30px !important;}”][vc_column][vc_separator][vc_column_text css=”.vc_custom_1549869386262{border-top-width: 1px !important;border-bottom-width: 1px !important;padding-bottom: 2px !important;border-top-color: #cccccc !important;border-bottom-color: #cccccc !important;}”]

We estimated the benefits of this solution to be:

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