New machine design
Linear stacker
Structural and mechanical assessment during design development
Project phase: design development
The engineering challenge
Developing a new linear stacker required the boom, counterweight, luffing system, travelling equipment and tripper to be assessed together. Changes to load assumptions or machine balance could improve one condition while increasing demand elsewhere.
ACE’s responsibility
ACE supported the manufacturer and project delivery team through structural and mechanical calculations, whole machine assessments and an AS 4324.1:2025 gap study.
Engineering assessment
The work examined stability and wheel reactions across the assessed loading conditions, together with luff cylinder forces, long travel requirements and buffer loads. Sensitivity studies investigated how retained material and counterweight affected machine behaviour. Structural assessments identified members, support arrangements and interfaces requiring further design attention.
AS 4324.1:2025 gap study
ACE reviewed the earlier technical requirements against AS 4324.1:2025 and identified design basis clarifications, recommended technical specification changes and further assessment needs.
The review distinguished changes associated with the new edition from existing requirements and gaps in supporting information. The resulting register identified required inputs and actions across connected disciplines, supporting coordination of the OEM’s detailed design.
Recommendations for detailed design
ACE compared design options and recommended actions for the OEM’s detailed design. The assessment showed how machine balance and mechanical forces affected the structure, travel equipment, wheel assemblies and tripper.
The project team received recommendations and an action register to coordinate the remaining engineering work. Design and verification items needing further work were recorded for the next project stages.