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Analysis and Design for Manufacturing of Deep-Reach Large Crusher De-Clogging Robot

Cheraghi, Mohammad Mahdi | 2025

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  1. Type of Document: M.Sc. Thesis
  2. Language: Farsi
  3. Document No: 58625 (08)
  4. University: Sharif University of Technology
  5. Department: Mechanical Engineering
  6. Advisor(s): Durali, Mohammad
  7. Abstract:
  8. The objective of this research is to analyze and design a robot for declogging in the feed opening of gyratory crushers installed in a mining operation to expedite the crusher's return to production. The robot must not only be capable of reaching a depth of approximately 17 meters but also possess mobility and the ability to perform operations such as breaking large rocks, excavation, and grasping and relocating objects at depth using specialized tools. Currently, declogging in the feed opening of large gyratory crushers at depth is performed using personnel and the deployment of machinery to the depth, which is highly costly and hazardous. To this end, forward and inverse kinematics models, actuator kinematics, and inverse dynamics based on the Newton-Euler method were first developed. Subsequently, to reduce costs and enhance efficiency, multi-objective optimization was conducted using the NSGA-II algorithm, minimizing link lengths while maximizing workspace, with design variables including the lengths of three arms and the start and end positions of the actuators. Based on the Pareto front, selected solutions were extracted, and their workspaces were plotted. Then, detailed component design was carried out, including the design of arms, calculations and design of actuators, joints, selection of appropriate tools, and their quick-connect mechanisms, followed by finite element analysis on critical components. The designed robot is mounted on an excavator to enable mobility. The results demonstrated that the proposed model significantly reduces costs and increases mine revenue, meeting the defined requirements while also offering potential for expansion to other similar industrial applications
  9. Keywords:
  10. De-Clogging Robot ; Serial Robot ; Kinematics ; Inverse Dynamics ; Workspace ; Hydraulic Actuators ; Dimensional Optimization ; Component Design

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