A COURSE PROJECT REPORT ON

DESIGN OF ELECTRIC COUNTERBALANCE STACKER

SUBMITTED BY

YASH VIJAYSINGH NEGI

ROHAN RAJESH RAWOOL

VEDANT SANTOSH SALVI

PARTH GANESH SANKHE

UNDER THE GUIDENCE OF

DR. ASHISH CHOUDHARI

DEPARTMENT OF MECHANICAL ENGINEERING

VIDYAVARDHINI’S COLLEGE OF ENGINEERING AND TECHNOLOGY

VASAI ROAD (W.)

UNIVERSITY OF MUMBAI

2024-2025
 VIDYAVARDHINI’S COLLEGE OF ENGINEERING AND TECHNOLOGY

VASAI ROAD (W.), THANE-401202

DEPARTMENT OF MECHANICAL ENGINEERING

CERTIFICATE
This is to certify that project entitled

DESIGN OF ELECTRIC COUNTERBALANCE STACKER

has been carried out by,

YASH VIJAYSINGH NEGI

ROHAN RAJESH RAWOOL

VEDANT SANTOSH SALVI

PARTH GANESH SANKHE

Students of final year B.E. MECHANICAL during SEM-VII(C-SCHEME)

under our supervision and guidance and submitted in accordance with
the syllabus prescribed for
“Design of Mechanical Systems”
In Mechanical Engineering of MUMBAI UNIVERSITY during academic
year 2024-25.

Dr. ASHISH CHAUDHARI Dr. UDAY ASWALEKAR Dr. RAKESH HIMTE

(Project Guide) (Head of Department) (Principal)

 DEPARTMENT OF MECHANICAL ENGINEERING

CONTENTS

Sr No Chapter Name Date Page No. Grade

Design of Electric Counterbalance Stacker
Assumptions Considered:
Overall Efficiency = 85 %
L10h = 12000 million. revolution
No. of teeth on pinion = 18, etc

1.1 Introduction 01
1.2 Problem Definition 02
1 1.3 Design of Fork 02 – 03
1.4 Selection of Motor 04 – 05
1.5 Selection of Bearing 05 – 06
1.6 Design of Gearbox 06 - 12
1.7 Design of Lifting Chain 12
1.8 Design of Mast 13
2
Results and Discussion 14
2.1 Summary of theoretical design dimensions 14
Details as well as Assembly Drawing sheet on A-3
2.2 14
paper using CAD software
3 Conclusion 15
 Chapter 1
(INTRODUCTION)

1.1. Introduction

An electric counterbalance stacker is a material-handling equipment used for

lifting, stacking, and transporting loads in industries and warehouses. Unlike
manual stackers, it operates with an electric drive and hydraulic lifting system,
which increases efficiency and reduces operator fatigue.
In this project, the design of an electric counterbalance stacker is carried out
considering load capacity, lifting height, stability, and material selection. The
major components include the mast, fork, hydraulic cylinder, roller chain,
sprocket system, and counterweight arrangement. The aim is to achieve a safe,
compact, and cost-effective design that can lift loads smoothly with proper
weight balance and minimum power consumption.

Fig.: Electric Counterbalance Stacker

Page.: 01
1.2. Problem Definition

The main problem identified is the need for a compact and efficient lifting
system that can handle heavy loads safely without using manual effort.

The objective of this project is:

• To design an electric counterbalance stacker with suitable dimensions,

materials, and components.

• To analyze the structural strength of key components such as the mast, fork,
and axle using standard mechanical design calculations.

• To select appropriate bearings, sprockets, roller chains, and hydraulic

systems for smooth and reliable operation.

• To ensure that the design maintains stability and prevents toppling during
load lifting.

1.3. Design of Fork

𝑊𝐿2
Mmax = −
2

Rated load = 2000 kg

W = 2000 × 9.81 = 19620 N
19620
W= = 9810 N
2

From (PSG 6.4),

9810 × (1200)2
Mmax = − …. Assume L = 1.2
2
m
Mmax = − 7.0632 × 103 N-mm

𝑏ℎ2
Z=
6
Page.: 02
 L 1200
b= = = 400 mm
3 3

400 × ℎ2
b=
6

Selection of the material for Fork,

40Cr1Mo60 Alloy Steel
Syt = 700 – 800 N/mm2
⸫ Syt = 700 N/mm2
Factor of Safety (F.O.S) = 3
Syt 700
σb = σt = = = 233.33 N/mm2
F.O.S 3

τ = 0.5 × σt = 0.5 × 233.33 = 116.66 N/mm2

M
σb =
Z

(7.0632 ×103 )
233.33 = 400 × ℎ2
6

h = 76.86 mm ≈ 80 mm

• Check in shear

P
τ=
A

Shear area (A) = b × h

9810
τ= = 0.30 N/mm2
400 ×80

τ = 0.30 N/mm2 < τall = 116.66 N/mm2

⸫ Design is safe

Page.: 03
1.4. Selection of Motor

W = 19620 N
Desired travel speed = 4 km/s = 1.11 m/s
Rolling resistance co – efficient = Cr r = 0.02 …. for rubber wheel on concrete

Force required at wheel,

Ftotal = Frolling resistance + Finertia force

Frolling resistance = Cr r × W
= 0.02 × 19620
= 392.4 N

v 1.11
Finertia force = m × a a= = = 0.27
t 4
m/s2
= 2000 × 0.27 …. Assume for 4 sec
= 555 N

In Ftotal = Fa + Fr + Fg

Fg = W × Slope

Slope is given in percentage = 10%

Fg = 19620 × 0.1 = 1962 N

Ftotal = 555 + 392.4 + 1962 = 2909.4 N

T = Ftotal × r
= 2909.4 × 100
T = 290940 N or 290.9 Nm

P = Ftotal × v
= 2909.4 × 1.11
P = 3228.99 W or 3.22 kW
Page.: 04
 From PSG 5.124
Assume Overall efficiency = 0.85
Po
ɳo =
Pi

3.22
0.85 =
Pi

Pi = 3.78 kW

So, Select power = 5.5 kW

Motor speed = 1500 rpm or 3000 rpm

• Calculating actual velocity

P = Ftotal × v
(5.5 × 103) = 2909.4 × v
⸫ v = 1.89 m/s

π×D×N
v=
60

π × 0.2 × N wheel
1.89 =
60

⸫ Nwheel = 180.48 ≈ 181 rpm

Gear box ratio,

N motor 3000
i= = = 16.57
N wheel 181

1.5. Selection of Bearing

Assume, L10h = 10000 hrs

60 × n × L 10h
L10 =
106

Page.: 05
 60 × 181 × 10000
L10 = = 108.6 million revolutions
106

C = P × (L10)1/p …. For taper roller bearing

Fa = 0

W 19620
Fr = = = 9810 N
2 2

P = (X × Fr + Y × Fa) × S.F
= 1 × 9810 × 1.2
P = 11772 N

C = 11772 × (108.6)10/3
C = 48039.57 N or 4803.9 kgf

Bearing d D B Static Dynamic

No. mm mm mm Capacity Capacity
(SKF) Co C
kgf kgf
32207A 35 mm 72 mm 23 mm 5080 kgf 5760 kgf

1.6. Design of Gearbox

R = 16.57

Considering 2 stage gear box

R = R1 × R2
R1 = R2
R = R1 2
R1 = √R
= √16.57
R1 = 4.070

Page.: 06
 Np Zg
Gear ratio, i = =
Ng Zp

Assume, minimum number of teeth on pinion (Zp) = 18

Zg
4.070 =
18

Zg = 73.27 ≈ 74 …. Note: To avoid hunting no. of teeth should be selected

so that they have no common factor other than 1.

⸫ Number of teeth of gear (Zg) = 75

Design of First stage spur gear

Step 1: No. of teeth

No. of teeth on pinion (Zp) = 18

No. of teeth on gear (Zg) = 75

Step 2: Selection of the Material

For pinion, 40Ni2Cr1Mo28 …. PSG 1.40

Sut = 1550 N/mm2
BHN = 444

For gear, 40Ni2Cr1Mo15 …. PSG 1.40

Sut = 1040 N/mm2
BHN = 630

Assume, Factor of Safety (F.O.S) = 4

Sut 1550
(So)p = = = 387.5 N/mm2
F.O.S 4

Sut 1040
(So)g = = = 260 N/mm2
F.O.S 4

Page.: 07
 Step 3: Lewi’s Form Factor

For 20° Full depth involute profile

0⋅912
Yp = π (0.154 − ) …. PSG 8.50
zP

0⋅912
= π (0.154 − )
18

Yp = 0.3246

0⋅912
Yg = π (0.154 − ) …. PSG 8.50
zg

0⋅912
= π (0.154 − )
75

Yg = 0.4456

Step 4: Compare Strength

Yp × Sop = 0.3246 × 387.5 = 125.78 N/mm2

Yg × Sog = 0.4456 × 260 = 115.85 N/mm2

As the strength of gear is less than the strength of the pinion; so we need to
design the gear

Step 5: Design of the gear

a. Static tooth load capacity (WS)

WS = σ × b × π × m × y …. PSG 8.52

Page.: 08
 where, σ = Allowable stress = 260 N/mm2
b = Face width of gear = (7 – 10) m = 10m
m = Module
y = Lewi’s Form Factor = 0.45

WS = 260 × 10m × π × m × 0.45

WS = 3675.663 m2

b. Tangential tooth load capacity (WT)

P
WT =
V

where, P = Power transmitted by motor = 5.5 kW

v = Tangential velocity of gear

π × Dg × Ng
= …. PSG 8.52
60000

π × m × Zg × Ng Np
= i=
60000 Ng

π × m × 75 × 368.55 1500
= 4.07 =
60000 Ng

v = 1.44 m ⸫ Ng = 368.55 rpm

5.5×103
WT =
1.44m

3819.44
WT =
m

c. Dynamic tooth load capacity (WD)

Neglect Inertia Load

WD = WT × Cv .... PSG 8.52

Page.: 09
 where, Cv = Barth’s velocity factor …. PSG 8.51

6+v
=
6

6 + 1.44 m
=
6

3819.44 6 + 1.44 m
WD = ×
m 6

d. For Safe Strength

WS = WD

3819.44 6 + 1.44 m
3675.663 m2 = ×
m 6

⸫ m = 1.09 mm

Selecting standard module,

⸫ m = 1.5 mm …. PSG 8.2

Data Pinion Gear

Module (m) 1.5 mm 1.5 mm
No. of teeth (Z) 18 75
Face width (b) = 10 × m 15 mm 15 mm
Pitch Circle Diameter (D) = m × Z 27 mm 112.5 mm
Addendum (a) = m 1.5 mm 1.5 mm
Dedendum (d) = 1.25 × m 1.875 mm 1.875 mm
Outer diameter (DO) = PCD + 2a 30 mm 115.5 mm
Inner diameter (Di) = PCD – 2d 23.25 mm 108.75 mm
Material 40Ni2Cr1Mo25 40Ni2Cr1Mo15
Strength (N/mm2) 1550 N/mm2 1040 N/mm2
Brinell Hardness Number (BHN) 444 630

Page.: 10
Step 6: Check for wear load

Bucking beam’s equation;

Fw = Dp × b × Q × k …. PSG 8.52

where, Dp = Diameter of pinion = 27 mm

b = Face width of gear = 15 mm
Q = Velocity ratio factor
k = Material combination factor

2 × Zg 2 × 75
Q= = = 1.613
Zg + Zp 75 + 18

S2es × sin ϕ 1 1
k= (Ep + Eg)
1⋅4

where, Ses = Allowable contact stress = 2.8 × (BHN)avg. – 70

= 2.8 × (537) – 70
Ses = 1433.6 N/mm2
Φ = Pressure angle = 20°
Ep = Eg = Young’s Modulus of Elasticity = 2.1 × 105 N/mm2

1433.62 × sin 20 1 1
k= (2.1×105 + 2.1×105 )
1⋅4

k = 4.782

Fw = 27 × 15 × 1.613 × 4.782

⸫ Fw = 3123.913 N

3819.44 6 + 1.44 × 1.5

WD = × = 3462.958 N
1.5 6

Page.: 11
 FW ≥ 0.5 × WD

3123.913 ≥ 0.5 × 3462.958

3123.913 ≥ 1731.479

⸫ Design is safe

1.7. Design of Lifting Chain

W = 19260 N

19260
W= = 9810 N
2

F.O.S = 5

Braking Load = Working Load × F.O.S

= 9810 × 5
= 49050 N
= 4905 kgf
= 4.90 tonnes

From PSG 7.72 (Roller Chain)

Chain Pitch Roller dia. Braking Load

No. mm mm kgf

10 A – 3 15.875 mm 10.16 mm 6660 kgf

Page.: 12
1.8. Design of Mast

Select Material C45 Steel

Critical load,
Euler’s Formula …. PSG 6.8

π2 × E × I
Pcritical =
Leff2

Mast is of rectangular hollow section

Standard = b × h × t

Assume b = 200 mm
b 200
h= = = 100 mm
2 2
E = 2.1 × 105 N/mm2 or 210 × 109 N/m2

Mast height = Max. lift height + Fork lift carriage +

Ground clearance
= 2500 + 500 + 125
= 3125 mm
⸫ L = 3.125 m

𝑏ℎ3 0.2 × 0.1 3

Moment of Inertia = = = 1.66 × 10-5 m4
12 12

π2 × 210 × 10 9 × 1.66 × 10 −5
Pcritical =
3.1252

Pcritical = 3.52 × 106 N or 3.52 MN or 3523.11 kN

As, Pactual < Pcritical

⸫ Design is safe

Page.: 13
 Chapter 2
(RESULT AND DISCUSSION)

2.1. Summary of theoretical design dimensions

The theoretical design of the electric counterbalance stacker was carried out
considering load, lifting height, and stability. The key dimensions and
selections are as follows: the fork length is 1200 mm, mast height is 3125 mm.
The roller chain selected is 10A3 with 25 links, paired with a sprocket of 20
teeth. Bearings used include GCr15 roller bearings. These dimensions and
component selections form the basis for the detailed CAD model and ensure
safe, efficient operation.

2.2. Details drawing sheet using CAD Software

Page.: 14
 Chapter 3
(CONCLUSION)

From the design and calculations, an efficient and stable electric counterbalance
stacker model has been developed. All major components were designed considering
strength, safety, and material availability. The design ensures smooth lifting through
a properly selected hydraulic cylinder, roller chain, and sprocket arrangement.

Further, the design has been tested to validate the theoretical calculations. This
project provides a foundation for calculating a working prototype with improved
ergonomics and higher lifting efficiency.

Page.: 15