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Client Case

Redesign of a bucket wheel for gold mining in South America

The challenge

A customer in South America asked us to improve the existing design of a bucket wheel. In practice, the original design was not achieving the desired production output and was subject to significant wear and tear. The goal: a robust and manufacturable design, fully compatible with the existing ladder and hydraulic system.

Our approach

After an initial design study, in which several possible solutions with their respective advantages and disadvantages were outlined, a preferred concept was selected together with the customer. Based on this concept, we designed a completely new bucket wheel, including the necessary components to realize the conversion:

  • Wheel and drive system modifications.
  • New inlet assembly and scraper
  • Adapter frame, matched to the existing ladder connection
  • Engineering and FEM analysis of structural components and ladder reinforcement
  • Details of the hydraulic connection, with special attention to maintenance accessibility
  • Complete 3D model and 2D production drawings, suitable for local fabrication
  • Parts list and cost estimate for manufacturing

Our experience with similar systems allowed us to quickly switch between design, structural analysis and practical detailing.

The result

  • A technically correct and immediately applicable design
  • Reduced risk during production and assembly
  • Full insight into required materials and costs
"Working with EQvolve gave us exactly the technical clarity and practical solutions we needed. They quickly understood our challenges and delivered a completely new bucket wheel design that was both stronger and easier to manufacture. The improved performance and reduced wear we've seen in operation prove the value of their expertise."

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