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At Dadi, a leading private enterprise specializing in bulk material conveying systems and high-end metallurgical equipment, we understand the critical role bridge-type scraper reclaimers play in modern bulk material handling—especially in industries such as steel, cement, power generation, and ports.

Bridge-type scraper reclaimers are engineered for continuous and automated reclaiming of bulk materials from stockpiles, providing efficiency, reliability, and operational consistency. However, like all mechanical systems operating under demanding conditions, they can occasionally face issues that affect performance or lead to downtime.

In this article, we’ll explore some of the most common problems encountered with bridge-type scraper reclaimers and provide practical troubleshooting and maintenance tips to keep them operating at peak performance.

1. Chain Tension and Wear

Issue: Uneven chain tension, excessive wear, or chain breakage.

Cause: Poor lubrication, improper alignment, or overloading.

Solution:

Conduct regular inspections to monitor chain elongation.

Ensure proper lubrication of chain links and sprockets.

Adjust tension uniformly on both sides to prevent skewing.

Replace worn chains promptly to avoid secondary damage.

2. Scraper Blade Damage or Misalignment

Issue: Scraper blades wear out quickly, bend, or fail to contact the material uniformly.

Cause: Improper blade material, misaligned track, or foreign material in the stockpile.

Solution:

Use abrasion-resistant materials for blades.

Check for track deformation or uneven surface along the reclaimer path.

Install protective screens or magnets upstream to prevent debris ingress.

3. Bridge Skewing and Structural Instability

Issue: The bridge frame tilts or drifts off alignment during operation.

Cause: Uneven chain drive, foundation settlement, or worn travel wheels.

Solution:

Calibrate both drive motors to maintain synchronized motion.

Perform periodic structural inspections of support frames and wheel housings.

Monitor and realign the bridge using sensors or manual adjustment tools.

4. Electrical and Control System Faults

Issue: Loss of control, unresponsive PLC system, or faulty sensors.

Cause: Dust contamination, electrical overloads, or outdated control software.

Solution:

Enclose electrical components in dust-proof cabinets with proper ventilation.

Implement surge protection and grounding.

Update software regularly and check signal integrity from all limit switches and encoders.

5. Hydraulic Failures (If Equipped)

Issue: Weak or jerky movements, pressure loss, or leakage.

Cause: Worn seals, contaminated fluid, or malfunctioning pump.

Solution:

Maintain clean hydraulic oil and replace filters as scheduled.

Inspect hoses and seals for signs of wear or leaks.

Monitor system pressure and replace faulty components proactively.

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