Shredder Hammer Lifter

Team: Halen Martini, Gabe Stagg and Matt Withers

Performance Review

Requirement / Constraint Target Threshold Predicted Performance Actual Performance
Device weight 350 lbs Under 4 Tons 292 lbs 329 lbs
Maximum width of object the device can lift N/A 4.75″ 4.875″ 4.920″
Device lift capacity N/A 500 lbs 500 lbs 500+ lbs
Device lifetime 20 years 8 years 20+ years Infinite
# of devices needed N/A 1 1 1
Eyelet diameter for crane hook connection N/A 2.5″ 2.5″ 2.5″

Static Force Analysis – Lift

A static analysis was performed on one side of the clamp.

Static Force Analysis – Lift
The static force analysis evaluates the equilibrium of the clamp assembly under maximum load conditions. By resolving the acting forces into horizontal and vertical components, the design ensures structural integrity of the lifting mechanism is maintained without mechanical deflection.

FEA Simulation – Lift and Lifetime

FEA Simulations were performed on the clamp arms (left) and bars (right) to analyze loads from clamping force and the hydraulic cylinder. Stress and Fatigue were analyzed.

Stress
FEA Stress – Arm
FEA Stress – Bar
Fatigue
FEA Fatigue – Arm
FEA Fatigue – Bar

CAD Model Review – Number of Devices, Weight, and Width

Hammers

Hammer - new
Hammer – Worn

Pin Protectors

Pin Protector – New
Pin Protector – Worn

The team placed the CAD of new (left) and worn (right) hammers and pin protectors inside the clamp to ensure a secure fit for both.

The projected weight of the clamp was collected from SolidWorks.

The side-view of the clamp was analyzed to verify the maximum width of hammer or pin protector.

Project Description

Western Metals Recycling (WMR) uses large hammers and pin protectors to shred metals. While shredding, the 500 lb hammers and pin protectors sustain significant damage and wear, requiring a 1–6 hour replacement on a weekly basis.

Shredder Rotor Photo
Shredder Rotor Photo
Parts/Debris Photo

We created a device that speeds up the replacement process and does not require welding. The device lifts worn and new hammers and pin protectors out of a rotor system during installation or removal.

Design Description

  1. Clamp Bars
  2. Clamp Arms
  3. Chamfered Containment Panels
  4. Load-Bearing Tapered Spacers
  5. Battery
  6. Electrical Components
  7. Receiver
  8. Hydraulic Cylinder
  9. Shackle
  10. Wireless Remote
CAD Assembly with Callouts 1–10. (starting at the top [noon] and going clockwise) 9, 1, 2, 3, 4, 5, 6, 7, 8. 10 is seperate and off to the left-hand side

Conclusion

Analysis Results

  • Static analysis shows a clamping safety factor of 3.43 (≥1500 lb capacity)
  • FEA gives a minimum tensile safety factor of 4.27
  • Fatigue life predicted at 1,000,000 cycles
  • Final weight: 329 lb (vs. 292 lb predicted)
  • Clamp width: 4.920 in (vs. 4.875 in. CAD)
  • One clamp can lift both hammers and pin protectors
  • Hardware and shackle verified to meet load requirements

Lessons Learned

  • Complex systems require multiple engineering disciplines
  • Electrical integration required outside expertise (WMR support)
  • Proactive scheduling is critical — manufacturing delays impacted timeline

Recommended Future Work

  • Develop a multi-clamp system mounted on a rod
  • Match clamp spacing to rotor layout
  • Enable simultaneous installation/removal
  • Move toward fully autonomous operation

Special thank you to Josh Fonger, Tyrel Skinner, and Preston Stith for their support in completing this project!