I

A Industry Oriented Mini Project on

Solar Stacker Machine

Submitted in Partial Fulfilment of the Requirements for the Award of the Degree of

BACHELOR OF TECHNOLOGY
IN
MECHANICAL ENGINEERING
Under
JNTU HYDERABAD

BY

K M ABDUL RAHMAN (18M25A0323)

MOHD GOUSE (18M25A0326)
SYED SHAFIUDDIN (18M25A0332)
MOHD FAZIL AHMED (18M25A0335)
MOHAMMED IMTIYAZ AHMED (18M25A0336)

Under the Esteemed Supervision of

Mr. SWAMY
Assistant Professor, Supervisor

DEPARTMENT OF MECHANICAL ENGINEERING

LORDS INSTITUTE OF ENGINEERING AND TECHNOLOGY
(Accredited by NAAC, Accredited by NBA, Approved by AICTE & Affiliated to JNTU,
Hyderabad) Survey No. 32, Himayath Sagar, Hyderabad-500091, India.

2019
 LORDS INSTITUTE OF ENGINEERING & TECHNOLOGY
Approved by AICTE/Affiliated to JNTUH/Estd.2002.

Accredited ‘A’ grade by NAAC Accredited by NBA

DEPARTMENT OF MECHANICAL ENGINEERING

Certificate

This is to certify that the project report entitled ‘SOLAR STACKER

MACHINE’’ is a bonafied of the work successfully completed and submitted by

K M ABDUL RAHMAN 18M25A0323

MOHD GOUSE 18M25A0326

18M25A0332
SYED SHAFIUDDIN
18M25A0335
MOHD FAZIL AHMED
18M25A0336
MOHAMMED IMTIYAZ AHMED

Under the guidance of Mr. SWAMY, Assistant Professor, Mechanical

Engineering Department for the Requirement of partial fulfillment for the award
of degree of Bachelor of Technology in Mechanical Engineering during the
academic year 2017-2021 from JNTUH.

Mr. SWAMY Dr. Syed Azam Pasha Quadri

Internal Guide HOD/ Vice Principal

Dr. C V Narasimhulu
External examiner
Principal
 LORDS INSTITUTE OF ENGINEERING & TECHNOLOGY
Approved by AICTE/Affiliated to JNTUH/Estd.2002. Accredited
‘A’ grade by NAAC Accredited by NBA

DEPARTMENT OF MECHANICAL ENGINEERING

Declaration
We hereby declare that the project document entitled “Solar Stacker
Machine” is a bonafide work done during the 4th year 1st semester of Bachelor of
Technology in Department of Mechanical Engineering. We also declare that the
work carried out is an authentic record of our own work under the guidance and
supervision of Mr. SWAMY, Department of Mechanical Engineering of Lords
Institute of Engineering and Technology.

This report has not been submitted to any other institute or university for
the award of any degree or diploma and neither this project is being used by
another person or people at any other place.

K M ABDUL RAHMAN 18M25A0323

MOHD GOUSE 18M25A0326
SYED SHAFIUDDIN 18M25A0332
MOHD FAZIL AHMED 18M25A0335
MOHAMMED IMTIYAZ AHMED 18M25A0336
 LORDS INSTITUTE OF ENGINEERING & TECHNOLOGY
Approved by AICTE/Affiliated to JNTUH/Estd.2002.
Accredited ‘A’ grade by NAAC Accredited byNBA

DEPARTMENT OF MECHANICAL ENGINEERING

Acknowledgement

MOHD GOUSE SYED SHAFIUDDIN MOHD FAZIL MOHAMMED

K M ABDUL
AHMED IMTIYAZ
RAHMAN
AHMED
(18M25A0323) (18M25A0326) (18M25A0332) (18M25A0335) (18M25A336)
+91 7799219819 +91 9985272553 +91 9848816625 +918886845058 +91 9052655592
kmrahma199 Mohdgouse041 Syedshafiuddin3 mdfazil7862 ma7630850
9@gmail.com @gmail.com 32@gmail.com @gmail.com @gmail.com

In the name of almighty, the most beneficent and the merciful, we thank the lord for
helping us in all the stages of this thesis work

We would like to thank our Guide Assistant Professor Mr. SWAMY for his aspiring
guidance and friendly advice during the project work. He was a constant motivation
throughout the project and took out some of his valuable time whenever it was required
for which we are very grateful to him. we would always be grateful for his motivation
and co- operation at various stages, which provided us the knowledge base and the
understanding of the potential projects in this field finally. We also appreciate the
concern of my parents, friends and other staff members at the college.
We express our sincere and deep gratitude to Dr. Syed Azam Pasha Quadri Vice all
the teaching and non-teaching staff of Lords Institute of Engineering and Techno
principal and Head of the Mechanical Department for his support throughout our
project and logy who has helped and cooperated with us. It gives us great pleasure
in acknowledging the support and help from my guide for his immense guidance
throughout the project.

Our experience here has been full of opportunities to learn from faculty with a wide
and deep expertise in Engineering. we would like to thank our beloved principal Dr.
C V Narsimhulu. And we would like to directly thank those people in the department
who were particularly instrumental in contributing to our experience at Lords Institute
of Engineering and Technology.

We thank both teaching and non-teaching staff members of mechanical department

for their kind cooperation and all sorts of help to bring out this project work
successfully

Lastly, we drive great pleasure and we would like to specially thank our parents for
their patience, continuous encouragement, support and love given towards completion
of our research work
 LORDS INSTITUTE OF ENGINEERING & TECHNOLOGY
Approved by AICTE/Affiliated to JNTUH/Estd.2002.
Accredited ‘A’ grade by NAAC Accredited by NBA

DEPARTMENT OF MECHANICAL ENGINEERING

Industry Oriented Mini Project Assessment process

PROGRAMME: UG DEGREE: B. TECH (MECHANICAL)

COURSE: INDUSTRY ORIENTED MINI
Year: IV SEM: I CREDITS: 2
PROJECT WORK

COURSE CODE: ME705PC UNIVERSITY: JNTUH REGULATION: R16

CONTACT HOURS: 3 Hours/Week.

Vision of the Institute:

Lords Institute of Engineering and Technology strives for excellence in professional education through
quality, innovation and teamwork and aims to emerge as a premier institute in the state and across the
nation.
Mission of the Institute:
• To impart quality professional education that meets the needs of present and emerging
technological world.
• To strive for student achievement and success, preparing them for life, career and leadership.
• To provide a scholarly and vibrant learning environment that enables faculty, staff and students
to achieve personal and professional growth.
• To contribute to advancement of knowledge, in both fundamental and applied areas of engineering
and technology.
• To forge mutually beneficial relationships with government organizations, industries, society and
the alumni.
 LORDS INSTITUTE OF ENGINEERING & TECHNOLOGY
Approved by AICTE/Affiliated to JNTUH/Estd.2002.
Accredited ‘A’ grade by NAAC Accredited by NBA

DEPARTMENT OF MECHANICAL ENGINEERING

Vision of the Department:

To impart high standards of quality education which enhance students’ career efficaciously, to become
a holistic well-qualified engineer who are competent, innovative, entrepreneurial and research oriented
to meet the standards of new millennium.

Mission of the Department:

DM1: An integrated educational approach that blends knowledge of engineering fundamentals, technical
skills, practical knowledge and research.

DM2: To enrich undergraduate experience of distinctive academic curriculum through interaction with
major stake holders, hands-on learning, team work, management and multi-disciplinary skill set.

DM3: To make students aware of professional responsibilities, ethics, global demands, sustainable
solutions, environmental, technological challenges and the needs of lifelong learning.

DM4: To prepare students in developing solutions of global standards through research and innovation,
design and development of demand-based projects, entrepreneurial skills and employability capabilities.

Note: DM: Department Mission

 VI

Program Outcomes (POs)

Engineering Graduates will be able to:

S.No. Program outcomes (POs):

1. Engineering knowledge: Apply the knowledge of mathematics, science, engineering
fundamentals, and an engineering specialization to the solution of complex engineering
problems.
2. Problem analysis: Identify, formulate, review research literature, and analyze complex
engineering problems reaching substantiated conclusions using first principles of
mathematics, natural sciences, and engineering sciences.
3. Design/Development of solutions: Design solutions for complex engineering problems and
design system components or processes that meet the specified needs with appropriate
consideration for the public health and safety, and the cultural, societal, and environmental
considerations.
4. Conduct investigations of complex problems: Use research-based knowledge and research
methods including design of experiments, analysis and interpretation of data, and
synthesis of the information to provide valid conclusions.
5. Modern tool usage: Create, select, and apply appropriate techniques, resources, and modern engineering and IT
tools including prediction and modeling to complex engineering activities with an understanding of the
limitations.
6. The engineer and society: Apply reasoning informed by the contextual knowledge to assess societal, health,
safety, legal and cultural issues and the consequent responsibilities relevant to the professional engineering
practice.
7.
Environment and sustainability: Understand the impact of the professional engineering solutions in societal and
environmental contexts, and demonstrate the knowledge of, and need for sustainable development.
Ethics: Apply ethical principles and commit to professional ethics and responsibilities and norms of the
8.
engineering practice.
9. Individual and team work: Function effectively as an individual, and as a member or leader in diverse teams,
and in multidisciplinary settings.
10.
Communication: Communicate effectively on complex engineering activities with the engineering community
and with society at large, such as, being able to comprehend and write effective reports and design documentation,
make effective presentations, and give and receive clear instructions.

11. Project management and finance: Demonstrate knowledge and understanding of the engineering and
management principles and apply these to one’s own work, as a member and leader in a team, to manage
projects and in multidisciplinary environments.

12. Life-long learning: Recognize the need for, and have the preparation and ability to engage in independent and
life-long learning in the broadest context of technological change.
 VII

Program Specific Outcomes (PSO’s)

Professional Skills: An ability to understand the basic concepts in Mechanical Engineering
PSO1 and to apply them to various areas, like production, thermal, designing etc., in the design
and implementation of complex systems

Problem-Solving Skills: An ability to solve complex Mechanical Engineering problems, using

PSO2 latest hardware and software tools, along with analytical skills to arrive cost effective and
appropriate solutions.

Details

The progress in the project work is to be presented by the middle of 3rd year 1st
semester before the evaluation committee. By this time, the students will be in a position
to publish a paper in international/ national journals/conferences. The EC can accept,
accept with modification, and request a resubmission. The progress of project work if found
unsatisfactory by the EC during the middle of the semester presentation, such students
has to present again to the EC at the end of the semester and if it is also found
unsatisfactory an extension of the project work can be given to the students.
The student's sectional marks for project will be 100 which will be awarded based on
the presentation of the project by the students before an evaluation committee, and external
examiner.

COURSE OBJECTIVES:
1. To give a platform for the students to apply the theoretical knowledge they gained
during the course and conduct analysis/manufacture working models.

2. To enable the students to use different design platforms for design and analysis of
project.

3. To give a chance to improve communication skills and enable the students to express
the theoretical knowledge to defend

4. To impart theoretical knowledge about Solar Stacker Machine

5. To give the students a feel of working in a team environment and contribute to the
success of the project.
 VIII

COURSE OUTCOMES: C418. INDUSTRY ORIENTED MINI PROJECT WORK

S.No DESCRIPTION Bloom's
Taxonomy
Level
C418.1 Ability to effectively gather and interpret information from literature Understand
survey. And use this knowledge to identify, formulate and fabricate, Level 2
and to evaluate and interpret various solutions
C418.2 Apply
Gain the ability to communicate effectively with written, oral, and
visual means in a technical setting. Level 3
C418.3 Ability to use modern design and analysis tools. Evaluate
Level 5
C418.4 Students will be able to carry out calculations involved in design, Apply
consider and evaluate alternate assumptions, approaches, and Level 3
procedures. Ability to fabricate system components related to
engineering problems giving considerations to environment and
society.
C418.5 Ability to serve as effective team member to plan and complete the Analyze
project/task within a specified budget and time. Level 4

CO-PO AND CO-PSO MAPPING

PO1 PO2 PO3 PO4 PO5 PO6 PO7 PO8 PO9 PO10 PO11 PO12 PSO1 PSO2
C418.1 3 3 3 3 - - - - - - - 3 3 3
C418.2 - - - - - - - - - 3 - - - -
C418.3 - 2 2 2 - - - - - - - - - -
C418.4 - 2 3 3 - - - - - - - - 3 3
C418.5 - - - - - - - - - - 3 - - -
3 2.3 2.6 2.6 - - - - - 3 3 3 3 3

JUSTIFICATIONS FOR CO-PO MAPPING

MAPPING Levels JUSTIFICATION

C418.1-P01 3 Students will be able to use the fundamental knowledge in the field
of engineering to solve the problems related to project work.
C418.1-P02 3 Students will be able to identify eco-friendly and consumer friendly
project and conduct a detailed or fresh design.
C418.1- P03 3 Students will be able to design project aiming social
responsibilities, minimized health impact and meeting customer
requirement.
C418.1-P04 3 Students will be able to conduct a thorough research, design and
fabrication of experiment setup and analysis of the obtained
result.
C418.1-P012 3 Students can earn self confidence in handling complex projects and
that will help in handling independent projects.
C418.2-P010 3 Students will be able to effectively communicate their i d e a s and
clarity the technical details behind design and implementation of
project.
 IX

C418.3-P02 2 Students will be able to use modern design and analysis tool prior to the
fabrication for synthesis.
C418.3-P03 2 Students will be able to use modern tools to design a product which is
customer friendly and environmentally sustainable.
C418.3-P04 2 Students will be able to use advance analysis software to conduct a
check on the functionality of the product.
C418.4-P02 2 Student will be able to make necessary design calculations and proper
selection of suitable materials.
C418.4-P03 2
Student will be able to design and develop products which give utmost
important to social, economic and environment sustainability.
C418.4-P04 2 Students will be able to design, fabricate and conduct performance testing
on the developed products and analysis the experiment
observation for further improvement.
C418.5- P011 Students will be evolved as a good team player with better managerial
2 skills

JUSTIFICATION FOR CO-PSO MAPPING

MAPPING LEVELS JUSTIFICATION

C418.1-PSO1 3 Students will be able to apply their knowledge in fundamentals to find

suitable solution to the problems.
C418.1- PSO2 3
Students will be able to make use of their understanding in the core areas
of mechanical engineering during the design and analysis.
C418.4-PSO1 3 Students will be able to make use of the advance technologies to develop
new product which can sustain for a long time.
C418.4-PSO2 3 Students will be able to come up with the products that has customer
Acceptance

Mr. SWAMY Dr. Syed Azam Pasha Quadri

Internal Guide HOD/ Vice Principal
 X

Abstract

Title: Fabrication and testing of Solar Stacking Machine

Stacking is one of the biggest challenges in industries like power plants, mining, material
exports etc., The manual handling or usage of dozers for stacking operation requires lot of time,
man power, money and also involves risk of accidents. In earlier days both the manual and
dozer operations were suitable for stacking of the materials like ores, coal, grains etc, due to
the less quantities and cheaper man power availability in the market.
Due to the rapid global development, the mining, power plant and material export capacities
of the countries are increasing by many folds. Which requires machine that can stack loose
material ranging from few 100’s to 1000’s of tons with least man power intervention, highest
availability and in economic way.
However conventional stacker consumes good amount of electricity, incurring huge power bills
to the companies. As a part of our project dissertation, we are planning to fabricate and test a
solar stacking machine with following advantages.
➢ No fossil fuel generated power is required

➢ No greenhouse gas emission

➢ Extra land is not required for installation of solar panels as they are directly mounted
on machine

Our project involves;

➢ Study of conveyors, solar panels, wheels, pulleys, motors etc.,

➢ Fabrication of solar stacking machine

➢ Testing

➢ Preparation of work book

 XI

INDEX
Declaration
Certificates
Abstract

CONTENT
Chapter Title Page no.
1 Introduction
2 Literature review
3 Methodology
4 Material Selection and Fabrication
5 Conclusion
References
 1

CHAPTER 1
INTRODUCTION
A stacker is a large machine used in bulk material handling. Its function is to pile bulk
material such as limestone, ores and cereals on to a stockpile.

Gold dredges in Alaska had a stacker that was a fixed part of the dredge. It carried over-
size material to the tailings pile.

Stackers are nominally rated for capacity in tons per hour (tph). They normally travel
on a rail between stockpiles in the stockyard. A stacker can usually move in at least two
directions

Fig no.1.1

Stackers are used to stack in different patterns, such as cone stacking and chevron
stacking. Stacking in a single cone tends to cause size segregation, with coarser material
moving out towards the base. In raw cone ply stacking, additional cones are added next
to the first cone. In chevron stacking, the stacker travels along the length of the stockpile
adding layer upon layer of material.

Stackers were originally manually controlled, with no means of remote control. Modern
machines are typically semi-automatic or fully automated, with parameters remotely
set. The control system used is typically a programmable logic controlle, with a human-
machine interface for display, connected to a central control system.

The solar stacker will have 3 mechanisms namely belt conveying, travelling and
slewing
 2

CHAPTER 2
Literature Review
2.1 Conveyor system

A conveyor system is a common piece of mechanical handling equipment that moves

materials from one location to another. Conveyors are especially useful in applications
involving the transportation of heavy or bulky materials. Conveyor systems allow quick
and efficient transportation for a wide variety of materials, which make them very
popular in the material handling and packing industries. Many kinds of conveying
systems are available, and are used according to the various needs of different
industries.

Industries that use conveyor system

Conveyor systems are used widespread across a range of industries due to the
numerous benefits they provide.

• Conveyors are able to safely transport materials from one level to another,
which when done by human labor would be strenuous and expensive.
• They can be installed almost anywhere, and are much safer than using a forklift
or other machine to move materials.
• They can move loads of all shapes, sizes and weights. Also, many have
advanced safety features that help prevent accidents.
• There are a variety of options available for running conveying systems,
including the hydraulic, mechanical and fully automated systems, which are
equipped to fit individual needs.

Care and maintenance of conveyor system

A conveyor system is often the lifeline to a company’s ability to effectively move

its product in a timely fashion. The steps that a company can take to ensure that it
performs at peak capacity, include regular inspections, close monitoring of motors and
reducers, keeping key parts in stock, and proper training of personnel. Increasing the
service life of your conveyor system involves: choosing the right conveyor type, the
right system design and paying attention to regular maintenance practices.

A conveyor system that is designed properly will last a long time with proper
 3

maintenance. Here are six of the biggest problems to watch for in overhead type
conveyor systems including I-beam monorails, enclosed track conveyors and power
and free conveyors.

2.1.1 Types of conveyors

➢ Belt conveyor.
➢ Pneumatic conveyor.
➢ Chain conveyor.
➢ Screw conveyor.
➢ Bucket conveyor.

2.1.1 Belt conveyor

A conveyor belt is the carrying medium of a belt conveyor system (often shortened to
belt conveyor). A belt conveyor system is one of many types of conveyor system. A
belt conveyor system consists of two or more pulleys (sometimes referred to as drums),
with an endless loop of carrying medium, the conveyor belt that rotates about them.
One or both of the pulleys are powered, moving the belt and the material on the belt
forward. The powered pulley is called the drive pulley while the unpowered pulley is
called the idler pulley.

There are two main industrial classes of belt conveyors; Those in general material
handling such as those moving boxes along inside a factory and bulk material
handling such as those used to transport large volumes of resources and agricultural
materials, such as grain, salt, coal, ore, sand, overburden and more.

The belt consists of one or more layers of material. Many belts in general material
handling have two layers. An under layer of material to provide linear strength and
shape called a carcass and an over layer called the cover. The carcass is often a woven
fabric having a warp &weft. The most common carcass materials are polyester, nylon
and cotton. The cover is often various rubber or plastic compounds specified by use of
the belt as shown in figure (2.1.1). Covers can be made from more exotic materials for
unusual applications such as silicone for heat or gum rubber when traction is essential.
 4

Figure (2.1.1) conveyor belt

Material flowing over the belt may be weighed in transit using a beltweigher.
Belts with regularly spaced partitions, known as elevator belt, are used for transporting
loose materials up steep inclines. Belt Conveyors are used in self-unloading bulk
freighters and in live bottom trucks. Belt conveyor technology is also used in conveyor
transport, such as moving sidewalks or escalators, as well as on many manufactures’
assembly lines. Stores often have conveyor belts at the check-out counter to
move shopping items. Ski areas also use conveyor belts to transport skiers up the hill.

Belt Conveyor Types

Permanent: This type of conveyors is installed for the life of the mine. They are used
in main line, slope, long overland installation, preparation plants and
stockpiles.

Portable: These are characterised by relative ease of assembling and disassembling

to facilitate advances and recovery in development and retreat operations
in underground mining. Portable conveyors mounted on crawler or
wheels are also used in mechanised quarries and surface mines.

Shiftable: Used in continuous surface mining this type of conveyor is mounted on

skid or supporting structures aligned together and the whole can be
shifted transversely to follow the advancing working face.
 5

High Angle Conveyor: These are special type of conveyor belt arrangement used for
negotiating steeper angle of inclination. Such belts can work in slope up
to 70-800. Sandwich belt conveyor is a type of such belt conveyor.

Cable Belt Conveyor: Where the belt is carried on moving wire ropes and the tractive
force is applied through the rope to the belt is known as cable belt
conveyor.

Belt conveyors are the most commonly used powered conveyors because they are the
most versatile and the least expensive. Product is conveyed directly on the belt so both
regular and irregular shaped objects, large or small, light and heavy, can be transported
successfully. These conveyors should use only the highest quality premium belting
products, which reduces belt stretch and results in less maintenance for tension
adjustments. Belt conveyors can be used to transport product in a straight line or
through changes in elevation or direction. In certain applications they can also be used
for static accumulation or cartons.

Belt conveyor safety system

Conveyors used in industrial settings include tripping mechanisms such as trip cords
along the length of the conveyor. This allows for workers to immediately shut down
the conveyor when a problem arises. Warning alarms are included to notify employees
that a conveyor is about to turn on. In the United States, the occupational safety and
health admistration has issued regulations for conveyor safety, as OSHA 1926.555.

Applications
Conveyor belts are widely used in mineral industry. Underground mine transport,
opencast mine transport and processing plants deploy conveyor belts of different kinds
to adopt the specific job requirements. The main advantages of conveyor belt system
are:

1. A wider range of material can be handled which pause problems in other

transportation means. Belt conveyor can be used for abrasive, wet, dry, sticky or
dirty material. The lump size of the transported material is limited by the width of
the belt. Belts up to 2500 mm wide are used in mining industry.
 6

2. Higher capacity can be handled than any other form of conveyor at a considerably
lower cost per ton kilometer. Conveyor belts with capacity of 11000t/h and even
higher can be deployed to match with higher capacity mining machinery.

3. Longer distances can be covered more economically than any other transportation
system. A single belt conveyor or a series of belt conveyors can do this. Belt
conveyors can be adopted for cross-country laying.

4. By the use of many forms of ancillary equipment such as mobile trippers or spreaders
bulk material can be distributed and deposited whenever required.

5. Many other functions can be performed with the basic conveying like weighing,
sorting, picking, sampling, blending, spraying, cooling, drying etc.

6. Structurally it is one of the lightest forms of conveying machine. It is comparatively

cheaper and supporting structures can be used for many otherwise impossible
structures such as crossing rivers, streets and valleys.

7. The belt conveyor can be adopted for special purposes (fire resistant, wear resistant,
corrosion resistant, high angle negotiation etc.) and can be integrated with other
equipment.

8. It can be horizontal, incline or decline or combination of all.

9. Minimum labor is required for the operation and maintenance of belt conveyor
system.

10. In underground mine transport, belt conveyor can be used in thin seams as it
eliminates the rock works that might otherwise be required to gain haulage height.
Moreover, belt conveyor can provide continuous haulage service from pit bottom to
the surface.

Limitations of conveyor belt

1. The loading and transfer points need to be properly designed.

2. Numbers of protective devices have to be incorporated to save the belt from getting
damaged by operational problems.
 7

3. The belt needs higher initial tension (40-200% of useful pull).

4. The use of belt is restricted by the lump size.

5. Conveying of sticky material is associated with problems of cleaning and discharge

causing poor productivity.

6. Higher elongation of the belt (4% elongation may take place at the working load).

Some of the applications of belt conveyors are shown in Figures below:

Fig.no.2.1.2

2.2 Idlers

Idler is a belt supporting roller. The idlers shall consist of cylindrical shells
mounted in such a way as to rotate about their longitudinal axis with diametrical run
out not more than 0.8mm the idlers shall be properly designed for strength, rigidity and
accuracy for the load and duty coordination’s to which these shall be subjected to keep
the out of balance forces to a minimum value. The idler shall be manufactured from
electrical resistance welded (ERW) are seamless steel tube.

2.2.1Types of idlers

 Carrying idlers.
 Return idlers.
 8

 Transition idlers.
 Impact idlers.
 Fixed idlers.
 Garland idlers.

Carrying idler

It is an idler upon which the load carrying portion of belting is supported.the basic types
of belt conveyor carrying idlers shall be

a) Troughing carrying idler: It is a carrying idler consisting of two or

more rollers so arranged as turn the edges of the belt upwards to form
the belt into a moving through it shall consisting of three roles of equal
length and may be either in line or offset type.
b) Plate carrying idler: It is an idler consisting of one or more rollers
supporting the belt in the first position as shown in figure (2.2.1). The
horizontal carrying idler for supporting Plate loaded belt shell consists
of one or more horizontal rollers.

Figure (2.2.1) Plate carrying idler

Return idler

It is the idler supporting the return run of the belt. These may be consist of a single idler
or a set of idlers. In case of a set of idlers, the idlers are of equal length and are placed
inclined to the horizontal to form a “V”. The angle of inclination of the idler is kept at
10* to the horizontal in this case. The letter arrangement is applicable to belt conveyors
with belts at least 800mm wide.
 9

a) Self cleaning return idler: These idlers are used to clean the belt
carrying sticky materials, whose abrasive actions wear the shell of the
return idler roll as shown in figure (2.2.2). A large buildup the sticky
materials may cause misalignment of the return run of the belt. Metal
cage, rubber disk and helical rolls used for this purpose present very
narrow surface for adhesion.

Figure (2.2.2) self-cleaning return idler

Transition idler

Transition type Troughing idler shall be used adjacent to the head and tail pulley and
adjacent to plough on troughed belt for wide, high tension low stretch belts as shown
in figure (2.2.3). This will prevent excessive stretch of the belt edges. The side idlers in
each transition idler set shall preferably be of adjustable type. However, the supplier
shall indicate the recommended spacing of the transition idlers set and angle of
inclination of side idler in each transition idler set.
 10

Figure (2.2.3) Transition idler

Impact idler:

It is belt idler having the rollers fitted with rings of resilient material absorb the shock
of loading material at loading point in to the conveyor belt to prevent damage to belt
and idlers as shown in figure (2.2.4). The rollers shall be fitted with rings of resilient
material to take care of the impact of the falling material on the belt. Load rate of impact
shall not be higher than those of the standard idlers.

Figure (2.2.4) Impact idler

Fixed idlers:

The figure of fixed idlers is shown in figure (2.2.5).

Figure (2.2.5) fixed idlers

 11

Garland idlers:

Garland idlers is shown in figure (2.2.6).

Figure (2.2.6) Garland idler

2.3 Pulleys:

A pulley is a wheel on an axle or shaft that is designed to support movement and change
of direction of a cable or belt along its circumference. Pulleys are used in a variety of
ways to lift loads, apply forces, and to transmit power. In nautical contexts, the
assembly of wheel, axle, and supporting shell is referred to as a "block."

A pulley may also be called a shave or drum and may have a groove between two
flanges around its circumference. The drive element of a pulley system can be a rope,
cable, belt or chain that runs over the pulley inside the groove.

These are different types of pulley systems:

• Fixed: A fixed pulley has an axle mounted in bearings attached to a supporting

structure. A fixed pulley changes the direction of the force on a rope or belt that
moves along its circumference. Mechanical advantage is gained by combining a
fixed pulley with a movable pulley or another fixed pulley of a different diameter.
• Movable: A movable pulley has an axle in a movable block. A single movable
pulley is supported by two parts of the same rope and has a mechanical advantage
of two.
• Compound: A combination of fixed and movable pulleys forms a block and tackle.
A block and tackle can have several pulleys mounted on the fixed and moving axles,
further increasing the mechanical advantage.
 12

2.3.1 Types of pulleys

Pulleys are manufactured in a wide range of sizes, consisting of a continuous rim and
two end discs fitted with hubs. In most of the conveyor pulleys intermediate stiffening
discs are welded inside the rim. Other pulleys are self-cleaning wing types which are
used as the tail, take-up, or snub pulley where material tends to build up on the pulley
face. Magnetic types of pulleys are used to remove tramp iron from the material being
conveyed.

There are different types of pulleys some of them are as follows.

 Drive pulley.
 Driven pulley.
 Head pulley.
 Tail pulley.
 Take up pulley.
 Bend pulley.
 Snub pulley.
 Rubber lagging pulley.

Drive pulley

Head/Drive Pulley is located at the discharge terminus of the conveyor as

shown in figure (2.3.1). It provides the driving force for the conveyor. In
order to increase pulley life and traction, it often has a larger diameter than
other pulleys.
 13

Figure (2.3.1) Drive pulley

Figure (2.3.2) Driven pulley

Figure (2.3.3) head pulley

Figure (2.3.4) tail pulley

Bend pulley
The bend pulley is used for changing the direction of the running or
increasing the wrap angle between the conveyor belt and the driving pulley.

As per different carrying capacities, the bend pulley can be divided into
their categories: light duty, medium duty, and heavy duty as shown in figure
 14

(2.3.5). The shift of the diameter can be 50~100mm, 120~180mm and

200~260mm and the structure is the same with the driving pulley.

Figure (2.3.5) Bend pulley

The bend pulley is usually installed at the tail part or the vertical
take-up equipment part when the belt direction need to 180* bending. It will
be installed above the take up equipment part while 90 * bending. The
pulley, which is used for extending the contact surface, is usually used for
below or equal to 45 degrees bending.

Figure (2.3.6) Snub pulley

 15

Figure (2.3.7) Rubber lagging

2.4 Motors

A motor is a mechanical or electrical device that creates motion.

An induction or asynchronous motor is an Ac electric motor in which the electric
current in the rotor needed to produce torque is obtained by electromagnetic
induction from the magnetic field of the stator winding. An induction motor therefore
does not require mechanical comutators, separate-excitation or self-excitation for all or
part of the energy transferred from stator to rotor, as in universal, DC and large
synchronous motors. An induction motor's rotor can be either wound type or squirrel
cage type.

AC motor

An AC motor is an electric motor driven by an alternating current (AC) as shown in

figure (2.4.1). The AC motor commonly consists of two basic parts, an outside
stationary stator having coils supplied with alternating current to produce a rotating
magnetic field, and an inside rotor attached to the output shaft producing a second
rotating magnetic field. The rotor magnetic field may be produced by permanent
magnets, reluctance saliency, or DC or AC electrical windings.

Less commonly, linear AC motors operate on similar principles as rotating motors but
have their stationary and moving parts arranged in a straight line configuration,
producing linear motion instead of rotation.
 16

Figure (2.4.1) AC motor

Operating principles

AC motors operate with two rotating (or moving) magnetic fields on the rotor and stator
respectively. Pulling or pushing the poles of the two magnetic fields along, the speed
of the stator rotating magnetic field (Ws) and the speed of the rotor rotating magnetic
field (Wr), which is relative to the speed of the mechanical shaft (Wm), must maintain
synchronism for average torque production by satisfying the synchronous speed
relation (i.e., ±Ws ±Wr = Wm). Otherwise, asynchronously rotating magnetic fields
would produce pulsating or non-average torque.

The two main types of AC motors are classified as induction or synchronous. The
induction motor (or asynchronous motor) always relies on a small difference in speed
between the stator rotating magnetic field and the rotor shaft speed called slip to induce
rotor current in the rotor AC winding. As a result, the induction motor cannot produce
torque about synchronous speed where induction (or slip) is irrelevant or ceases to exist.
In contrast, the synchronous motor does not rely on slip-induction for operation and
uses either permanent magnets, salient poles (having projecting magnetic poles), or an
independently excited rotor winding. The synchronous motor produces its rated torque
at exactly synchronous speed. The brushless wound-rotor doubly-fed synchronous
motor system has an independently excited rotor winding that does not rely on the
principles of slip-induction of current. The brushless wound-rotor doubly-fed motor is
a synchronous motor that can function exactly at the supply frequency or sub to super
multiple of the supply frequency.
 17

DC motor

A DC motor as shown in figure (2.4.2), is any of a class of electrical machines that

converts direct current electrical power into mechanical power. The most common
types rely on the forces produced by magnetic fields. Nearly all types of DC motors
have some internal mechanism, either electromechanical or electronic; to periodically
change the direction of current flow in part of the motor. Most types produce rotary
motion; a linear motor directly produces force and motion in a straight line.

Figure (4.2.2) DC motor

DC motors were the first type widely used, since they could be powered from existing
direct-current lighting power distribution systems. A DC motor's speed can be
controlled over a wide range, using either a variable supply voltage or by changing the
strength of current in its field windings. Small DC motors are used in tools, toys, and
appliances. The universal motor can operate on direct current but is a lightweight motor
used for portable power tools and appliances. Larger DC motors are used in propulsion
of electric vehicles, elevator and hoists, or in drives for steel rolling mills. The advent
of power electronics has made replacement of DC motors with AC motors possible in
many applications.

2.5 Bearings

A bearing is a machine element that constrains relative motion to only the desired
motion, and reduces friction between moving parts. The design of the bearing may, for
example, provide for free linear movement of the moving part or for free rotation
around a fixed axis; or, it may prevent a motion by controlling the vectors of normal
 18

forces that bear on the moving parts. Many bearings also facilitate the desired motion
as much as possible, such as by minimizing friction. Bearings are classified broadly
according to the type of operation, the motions allowed, or to the directions of the loads
(forces) applied to the parts.

A bearing is a machine element that allows one part to bear (i.e., to support) another.
The simplest bearings are bearing surfaces, cut or formed into a part, with varying
degrees of control over the form, size, roughness and location of the surface. Other
bearings are separate devices installed into a machine or machine part. The most
sophisticated bearings for the most demanding applications are very precise devices;
their manufacture requires some of the highest standards of current technology.

Types of bearing

A mechanical bearing as shown in figure (2.5.1), is a component used between two

parts that allows rotational or liner movement, reducing friction and enhancing
performance to save energy. Both metal and plastic bearings can be found everywhere,
from refrigerators to computers to the 100 or so bearings found in your car. The concept
behind them is a simple one: things roll better than they slide. Without bearings, the
wheels in your car would rattle, the transmission gear teeth wouldn’t be able to mesh,
and the car wouldn't run smoothly. They are composed of a smooth inner and outer
metal surface for metal balls to roll against. The balls or rollers help “bear” the load and
the device functions more efficiently.

Figure (2.5.1) bearings

There are many different types of bearings, each used for specific purposes and
designed to carry specific types of loads, radial or thrust. Here, we’ll look at the 6 most
 19

popular types: plain bearings, rolling element bearings, jewel bearings, fluid bearings,
magnetic bearings, and flexure bearings.

1) Plain Bearings

Plain bearings are the simplest type of bearing and are composed of just the bearing
surface with no rolling elements. They have a high load-carrying capacity, are generally
the least expensive and, depending on the materials, have much longer lives than other
types.

2) Rolling Element Bearings

Rolling element bearings place balls or rollers between two rings - or “races” - that
allows motion with little rolling resistance and sliding. These bearings include ball
bearings and roller bearings.

Ball bearings are the most common type of rolling element bearing. These bearings can
handle both radial and thrust loads but are usually used where the load is relatively
small. Because of its structure, there is not a lot of contact with the balls on the inner
and outer races. If the bearing is overloaded the balls would deform and ruin the
bearing. Roller bearings are able to handle a much heavier, radial load, like conveyor
belts, because they don’t use balls. Instead, they have cylinders allowing more contact
between the races, spreading the load out over a larger area. However this type of
bearing is not designed to handle much thrust loading

Jewel Bearings

Jewel bearings are plain bearings with a metal spindle that turns in a jewel-lined pivot
hole as shown in figure (2.5.2). They carry loads by rolling the axle slightly off-center
and are usually used in mechanical watches or clocks. This is due to their low and
predictable friction that improves watch accuracy.
 20

Figure (2.5.2) jewel bearing

Fluid Bearings

Fluid bearings as shown in figure (2.5.3) support their load using a thin layer of gas or
liquid and can be classified into two types: fluid-dynamic bearings and hydrostatic
bearings. Fluid-dynamic bearings use rotation to form the liquid into a lubricating
wedge against the inner surface. In hydrostatic bearings, the fluids - usually oil, water,
or air - rely on an external pump. Fluid bearings are used in high load, high speed or
high precision applications that ordinary ball bearings either couldn’t handle or would
suffer from increased vibration and noise.

Figure (2.5.3) fluid bearing

 21

Magnetic Bearing

Magnetic bearings as shown in figure (2.5.4)support moving parts without physical

contact, instead relying on magnetic fields to carry the loads. They require continuous
power input to keep the load stable, thus requiring a back-up bearing in the case of

power or control system failure.

Figure (2.5.4) Magnetic bearing

Magnetic bearings have very low and predictable friction and the ability to run without
lubrication or in a vacuum. They are increasingly used in industrial machines like
turbines, motors, and generators.

Flexure Bearing

A typical flexure bearing as shown in figure (2.5.5) is one part joining two others, like
a hinge, in which motion is supported by a load element that bends. These bearings
require repeated bending, so material selection is the key. Some materials fail after
repeated bending, even at low loads, but with the right materials and bearing design the
flexure bearing can have an indefinite life. Another notable characteristic of this bearing
is its resistance to fatigue. Many other bearings that rely on balls or rollers can fatigue
as the rolling elements Plateten against each other.
 22

Figure (2.5.5) Flexture bearing

CHAPTER 3
Methodology
Solar stacker can be used to stack the bulk materials in stock yard with great power
economy
The machine will mainly consists of 3 mechanisms / operations
1. Conveyor

Conveyor transports material from tail end to head end with the help of belt
and pulleys
2. Travel

Main trolley on which the conveyor is mounted travels from one end of the
stock yard to other end of the stock yard used to cover length of the stock yard
3. Slewing

Slewing is boom rotation to cover width of the stock yard

 23

CHAPTER 4
Material Selection and Fabrication
Material Selection
Mild steel square pipe is used for fabrication of chassis as it is cheaper and easy to
fabricate.
10 and 3.5rpm geared motors are used for mechanisms as they have good torque and
control. For real case we may use hydraulic drives.
Mild steel plate is used for motor support due to its low cost and ease of
manufacturing
4.1 Trolley:
We have taken a plate of width 70mm as shown in figure (4.1.1).

Fig (4.1.1) plate

Plate is marked at 200mm distance from its edge and within this marked area on plate; we have
 24

done another markings for drilling operation as shown in figure (4.1.2).

Fig (4.1.2) marking on plate

Drilling is done with 13mm drill bit with respect to the intersection markings as shown in figure
(4.1.3).

Fig (4.1.3) drilling on plate

Plate is then cut at 200mm distance as shown in figure (4.1.4).
 25

Fig (4.1.4) cutting on plate

We have obtained 2 plates of length 200mm with drills by following above mentioned process.
We have taken a square pipe of width 19mm and thickness 2mm as shown in figure (4.1.5).

Fig (4.1.5) square pipe

We have marked the pipe at distance 300mm from its edge as shown in figure (4.1.6).
 26

Fig (4.1.6) marking on pipe

Cutting is performed at the marked location as shown in figure (4.1.7).

Fig (4.1.7) cutting of pipe

Grinding of the pipe is done to get some surface finish as shown in figure (4.1.8).
 27

Fig (4.1.8) grinding of pipe

We have obtained 2 pipes of length 300mm by following above mentioned process.
We have welded square boxes with the drilled 200mm length plates as shown in figure (4.1.9).

Fig (4.1.9) welding of plates and boxes

4.2 Conveyor:
We have taken a plate of width 70mm as shown in figure (4.2.1).
 28

Fig (4.2.1) plate

Plate is marked at 40mm distance from its edge and within this marked area on plate; we have
done another markings for drilling operation as shown in figure (4.2.2).

Fig (4.2.2) marking on plate

Drilling is done with 13mm drill bit with respect to the intersection markings as shown in figure
(4.2.3).
 29

Fig (4.2.3) drilling on plate

Plate is then cut at 40mm distance as shown in figure (4.2.4).

Fig (4.2.4) cutting on plate

We have obtained 4 plates of length 40mm with drills by following above mentioned process.
We have taken a PVC pipe of dia 42mm and end caps as shown in figure (4.2.5).
 30

Fig (4.2.5) PVC pipe and end cap

We have marked the PVC pipe at 115mm distance and a center marking is done on the end caps
as shown in figure (4.2.6).

Fig (4.2.6) marking on PVC pipe and end cap

Operation of cutting is performed on pipe and drilling of 13mm hole is done on caps as shown
in figure (4.2.7) & figure (4.2.8).
 31

Fig (4.2.7) cutting of pipe

Fig (4.2.8) drilling on end caps

We have fixed the end caps to the pipes and obtained 2 conveyor pulleys of total length 120mm.
A 12 outer diameter and 6 inner diameter MS pipe is taken as shown in figure (4.2.8).
 32

Fig (4.2.8) MS pipe

We have marked the pipe at 155mm distance as shown in figure (4.2.9).

Fig (4.2.9) marking on pipe

Cutting is performed on the pipe with respect to the markings as shown in figure (4.2.10).
 33

Fig (4.2.10) Cutting of pipe

Grinding and facing of pipe is done as shown in figure (4.2.11).

Fig (4.2.11) grinding and facing of pipe

We have fixed the pipe inside the conveyor pulley drills.

We have taken a plate of width 100mm and thickness 2mm as shown in figure (4.2.12).
 34

Fig (4.2.12) plate

We have marked the plate at 400mm from its edge as shown in figure (4.2.13).

Fig (4.2.13) marking on plate

We have performed cutting operation on the plate with respect to the markings as shown in
figure (4.2.14).
 35

Fig (4.2.14) cutting of plate

Drill plates are welded to this 400mm length plate as shown in figure (4.2.15).

Fig (4.2.15) Welding of drill plates

We have obtained a conveyor as shown in figure (4.2.16).

 36

Fig (4.2.16) Conveyor

 37

CHAPTER 5
Conclusion
➢ Stacker boom conveyor is able to transport material from one end
to the other end

➢ 180Deg slewing is achieved and is enough to cover width of the

stock yard

➢ Stacker is able to travel from one end to other

➢ All the power requirements can be met using solar panels

 38

References
1. "Tenova TAKRAF. (2007). Tenova Takraf Mining Equipment". Archived
from the original on 2011-12-06. Retrieved 2010-03-10.
2. "Earth Eating Monster" Popular Mechanics, June 1956, pp. 114-115
3. Jump up to:a b c d "Big Wheels Keep on Turning". womp-int.com.
4. Jump up to:a b c d Grathof, H. (1986). Design (Constructional Characteristics)
of Large Bucket Wheel Excavators. Journal of Mines, Metals, and Fuels,
34(4), 204-213.
5. Chironis, N. (1984). Bucket Wheel Excavators of Compact Design Growing
Popular. Coal Age, 84(10), 84-91.
6. ThyssenKrupp Fördertechnik. (2005). Business Unit:
MiningArchived February 11, 2011, at the Wayback Machine