A stacker may be a large machine utilized in bulk material handling. Its function is to pile bulk material like limestone, ores and cereals on to a stockpile. A reclaimers can be used to recover the material.
Stackers are nominally rated for capacity in tons per hour (tph). They normally travel on a rail between stockpiles within the stockyard. A stacker can usually move in a minimum of two directions: horizontally along the rail and vertically by luffing (raising and lowering) its boom. Luffing of the boom minimizes dust by reducing the space that material like coal must fall to the highest of the stockpile. The boom is luffed upwards because the height of the stockpile increases. Some stackers can rotate the boom. This allows one stacker to make two stockpiles, one on either side of the conveyor.
Stackers meaning is to stack in several patterns, like 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 primary cone. In chevron stacking, the stacker travels along the length of the stockpile adding layer upon layer of fabric.
Stacker machines and stacker reclaimers were originally manually controlled, with no means of remote. Modern machines are typically semi-automatic or fully automated, with parameters remotely set. The system used is usually a programmable logic controller, with a human-machine interface for display, connected to a central system.
Other than stacking, a stacker has three basic movements:
Luffing: This is vertical movement. Stackers use either a winch mechanism with metal wire, or hydraulic cylinders, generally two. Winch mechanisms are highly reliable compared to hydraulic actuators and remain widely used, particularly in large stackers.
Travelling: The stacker moves on a rail track, which can be broad or railroad track, enabling it to maneuver round the stockyard as needed. For this purpose, traction motors powered by DC (DC) are connected by bevel gears to between 12 and 22 wheels. For manual control, all the controls are during a controller's cabin above the boom conveyor or boom. Modern stackers can be controlled remotely.
Slewing: this is often rotation of the stacker around its central axis to align or place the stockpile where required. This works mostly by a slew pinion that rotates around a slew base. This type of gear assembly is called a sun and planet gear. The axles could also be multiple and are driven by DC-powered axle motors which transmit the torque via bevel or helical gears.
The conveyor belts utilized in stackers could also be made from fabric or metal wire, depending upon the fabric to be handled. They are driven by pulleys, which successively are driven by DC motors. The motors and kit are coupled by fluid coupling.
Most stackers are electrically powered by way of a trailing cable. There are basically two sorts of cable trailing: cord rotating drum (PCRD) and control cable rotating drum (CCRD). Pendulum adjustments are made to make sure the right alignment of those cables while the stacker is travelling.
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