Multi-functional Mining Machine Boom and Conveyor System

This project is a continuation of a 2018 senior design project to replace the Caterpillar 7495 electric rope shovel as the primary method for surface mining excavation. The new design focuses specifically on the machine’s material removal (boom, stick and bucket) and material transport (conveyor and feeder) subsystems. The design optimizes the mining process, reducing the time spent in the swing cycle by existing rope shovels by introducing continuous mining methods. The machine’s primary requirement was to achieve a material loading rate of 200 tons per minute while operating in an environment requiring a 70-foot horizontal reach and a 30-foot vertical reach. The team conducted extensive research, trade studies, CAD modeling and analysis to verify the system design and performance. They demonstrated the machine geometry of structural components with 3D models.