Automated Rod Mill Loader Design

About the project

Backgroubnd: A rod mill is a rotating grinding machine that uses steel rods to crush and grind ore or other materials into smaller particles. A rod mill rod charger is a mechanical loading system used to safely store, handle, and feed steel grinding rods into a rod mill. It reduces manual handling, improves safety, and allows controlled rod delivery during mill maintenance or operation, supporting efficient grinding performance and easier rod replacement. A rod mill rod charger mainly consists of a rod storage bench, where the bundle of grinding rods is placed, a rod indexing system to separate and control individual rods, a transfer mechanism to move each rod from the bench to the loader boom, and a rod mill loader boom that delivers the rod into the mill. The charger also includes a rail-mounted travel mechanism, allowing the unit to move forward and backward so the boom can be positioned and extended into the mill for safe and controlled rod loading. Main components include: * Rod storage bench for holding the grinding rod bundle * Rod indexer to separate and position individual rods * Transfer mechanism to move rods from the bench to the loader boom * Rod mill loader boom to carry and feed rods into the mill * Rail-mounted travel mechanism for forward and backward movement * Boom extension mechanism to allow the boom to enter the mill The existing rod mill rod charger is manually operated, with hand indexing of the grinding rods and manual movement of the loader boom into the rod mill for loading. After the rods are transferred onto the rod mill loader boom through the indexer, they are conveyed into the mill by a series of rotating drums driven by an electric motor. Existing data includes a 3D laser scan of the rod mill charger and surrounding area for design verification and modelling. The concept design has been finalised. The proposed modification includes using a pneumatic cylinder to rotate the rod indexer and a rack-and-pinion drive system to move the rod mill loader boom into and out of the mill in a controlled manner. The scope includes the design of a rod mill loader boom similar to the existing arrangement. The new boom shall be supported from the same existing support locations and maintain similar overall weight, dimensions, and operating envelope where practical. The design scope included not limited : * Design of the bench and indexer * Design of the stationary support frame * Design of the travelling / tracking boom * Design of the connection between the stationary frame and tracking boom * Design of a rack-and-pinion mechanism to move the boom into and out of the mill * Design of the rotating drum mechanism to move grinding rods along the boom and into the mill * Integration with the existing rod mill charger layout and support points * Consideration of similar weight, dimensions, and functionality to the existing loader boom The scope shall include all required mechanical, electrical, and pneumatic systems. All components shall be standard industrial items, readily available in Australia, and selected in accordance with applicable Australian Standards. Special or uncommon custom-order items shall be avoided. Deliverables: * 3D model native files in Autodesk Inventor * General Arrangement drawing and Fabrication drawings * Mechanical design calculations and Finite Element Analysis report Job Sequence: 1. Client provides the 3D laser scan data. 2. Contractor develops the design model and submits it for review. 3. Client reviews the model and provides comments. 4. Contractor addresses comments and updates the model. 5. Contractor prepares the FEA and submits it for review. 6. Client reviews the FEA and provides comments. 7. Contractor addresses comments and finalises the design. 8. Contractor prepares the final drawings. Estimated duration: 2 to 4 weeks from receipt of the required information and client approval comments.

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