i-manager's Journal on Mechanical Engineering (JME)


Volume 15 Issue 3 July - September 2025

Research Paper

Integration of Autonomous Robotic Material Handling for Enhanced Safety in Zimbabwean Platinum Mining: A Case Study of Mimosa Mine

Tafadzwa Mukodi* , Rindai P. Mahoso**, Godfrey Tigere***
*-*** Harare Institute of Technology, Harare, Zimbabwe.
Mukodi, T., Mahoso, R. P., and Tigere, G. (2025). Integration of Autonomous Robotic Material Handling for Enhanced Safety in Zimbabwean Platinum Mining: A Case Study of Mimosa Mine. i-manager’s Journal on Mechanical Engineering, 15(3), 1-19.

Abstract

Despite significant investments in mechanization and infrastructure, platinum mining operations in Zimbabwe, especially at Mimosa Mine, continue to experience major safety issues associated with manual material handling. Frequent incidents such as winch rope entanglement, equipment collisions, and rockfalls during stope cleaning have resulted in fatalities, emphasizing the pressing need for enhanced safety interventions. While autonomous solutions like robotic loaders and sensor-based geofencing have been shown to reduce accidents by up to 50% in international contexts, these technologies have yet to be widely implemented in Zimbabwe's underground platinum mining sector. This research paper develops an autonomous robotic material handling system tailored for the underground environment at Mimosa Mine, aiming to address critical safety risks and improve operational efficiency in high-risk activities. By focusing on automation of hazardous tasks and aligning with sustainability objectives, the proposed system provides a scalable approach to reducing human exposure to dangerous conditions and enhancing productivity. The study's outcomes highlight the transformative potential of autonomous systems for mining safety in Zimbabwe, while also recognizing ongoing operational challenges, such as power instability and fragmented supply chains.

Research Paper

Design and Motion Analysis of 14 Links Mechanism for One Degree of Freedom Robotic Legs and Prosthetics: Redefining Mobility

Azaka Onyemazuwa Andrew* , Okeke Chisom Agatha**, Ezenwafor Izuchukwu Sixtus***, Eze Godwin Chukwuemerie****, Odeh Calistus Princewill*****, Osazuwa Orobosa Kingsley******
*-****** Department of Mechanical Engineering, Nnamdi Azikiwe University, Awka, Anambra, Nigeria.
Andrew, A. O., Agatha, O. C., Sixtus, E. I., Chukwuemerie, E. G., Princewill, O. C., and Kingsley, O. O. (2025). Design and Motion Analysis of 14 Links Mechanism for One Degree of Freedom Robotic Legs and Prosthetics: Redefining Mobility. i-manager’s Journal on Mechanical Engineering, 15(3), 20-32.

Abstract

This study presents the design and motion analysis of a 14-link, single degree of freedom (DOF) mechanism for robotic legs and prosthetics. Through systematic number synthesis based on link mobility equations, 23 valid link combinations were generated that satisfy the condition of one DOF. Among these, the configuration consisting of 8 binary, 4 ternary, and 2 pentagonal links was selected because it is the only combination that incorporates pentagonal links, enabling a structurally rich, multi-loop architecture capable of coordinating complex hip, knee and ankle motion from a single actuator. The presence of two pentagonal links, each with five connection points, allows for strategic placement of joints and transmission elements, facilitating synchronized flexion and extension that closely mimic human gait kinematics. A 3D CAD model was developed in SOLIDWORKS and subjected to motion simulation, yielding a functional range of motion with 120° flexion and 37.6° extension. The mechanism achieves smooth articulation with a maximum angular velocity of 33.42 deg/s and acceleration of 33.04 deg/s², driven by a constant velocity rotor (300 deg/s). Simulink-based control system analysis confirmed stability, with an open-loop response exhibiting 10% overshoot and a 2-second settling time. A transfer function was derived from simulated input-output data, and system stability was further verified through pole-zero mapping, frequency response, and root locus analysis. By leveraging topological complexity rather than actuation redundancy, this work demonstrates that a single DOF mechanism can achieve biomimetic motion through intelligent link arrangement. The selected 14-link configuration provides a foundation for future integration of force analysis, lightweight materials, and experimental validation, offering a promising pathway toward adaptive, energy- efficient robotic leg systems.

Research Paper

Heat Transfer Enhancement in Heat Exchangers with Thermal Boundary Layer: A Numerical Study

Rajesh Davala* , V Ramachandra Raju**
* Department of Mechanical Engineering, Jawaharlal Nehru Technological University-GV College of Engineering Vizianagaram, Andhra Pradesh, India.
** Department of Mechanical Engineering, University College of Engineering, Jawaharlal Nehru Technological University, Kakinada, Andhra Pradesh, India.
Davala, R., and Raju, V. R. (2025). Heat Transfer Enhancement in Heat Exchangers with Thermal Boundary Layer: A Numerical Study. i-manager’s Journal on Mechanical Engineering, 15(3), 33-49.

Abstract

Enhancing the thermal performance of heat exchangers while minimizing flow resistance is critical for efficient energy systems. This study focuses on the effect of varying blade counts (2, 4, 6, and 8 blades) and Reynolds numbers (6000, 8000, 10,000, 12,000, and 14,000) on the thermal performance factor (TPF), friction factor, and heat transfer coefficient in thermal boundary layer heat exchangers. Numerical analyses were conducted to generate comprehensive datasets capturing the influence of blade-induced swirl and turbulence intensification across the specified Reynolds number range. An Artificial Neural Network (ANN) was developed and trained using these datasets to predict thermal and hydraulic performance with high accuracy. The model was used to optimize design parameters, identifying configurations that maximize heat transfer enhancement while controlling frictional penalties. Results indicate that increasing blade count significantly improves the heat transfer coefficient and TPF, especially at higher Reynolds numbers, but also leads to a corresponding increase in friction factor. The ANN demonstrated excellent predictive capability, offering a reliable tool for design optimization and performance prediction in thermal boundary layer heat exchangers with high Reynolds numbers and high blade counts. This work provides valuable insights into the interplay between blade geometry and flow conditions and demonstrates the effectiveness of AI-assisted modeling for the next generation of compact, high-performance heat exchangers.

Review Paper

Advances in Real-Time Data-Driven Scheduling and Optimisation in Dairy Manufacturing: Insights from Smart Yoghurt Production at Kefalos Cheese Pvt Ltd in Zimbabwe

Panashe S. Marivadzi*
Harare Institute of Technology, Harare, Zimbabwe.
Marivadzi, P. S. (2025). Advances in Real-Time Data-Driven Scheduling and Optimisation in Dairy Manufacturing: Insights from Smart Yoghurt Production at Kefalos Cheese Pvt Ltd in Zimbabwe. i-manager’s Journal on Mechanical Engineering, 15(3), 50-55.

Abstract

This review paper synthesizes recent research and practical developments in real-time data-driven scheduling and optimisation within the dairy manufacturing sector, with a particular focus on smart yoghurt production processes. Emphasis is placed on critical operational parameters such as machine utilisation, changeover times, demand variability, and batch size management and their influence on key production performance indicators. The integration of Industry 4.0 technologies, including IoT sensor networks, OPC UA data acquisition protocols, and advanced simulation- optimisation frameworks built in MATLAB/Simulink, is examined as enabling pillars of adaptive scheduling. Practical case studies from dairy manufacturers worldwide share quantified improvements in production efficiency and schedule robustness. Attention is given to challenges and opportunities for implementing such data-driven scheduling techniques in emerging economies, highlighting the case of Kefalos Cheese Pvt Ltd in Zimbabwe. Gaps for future research and technology adoption are outlined to guide continued advancements in smart dairy manufacturing systems.

Review Paper

Artificial Intelligence in the Energy Sector: Enhancing Boiler Performance with Advanced Thermal Spray Coatings

Harshit Garg* , Keshav Gulati**, Divyanshu Mittal***
*-*** Department of Computer Science and Engineering, CGC College of Engineering, Punjab, India.
Garg, H., Gulati, K., and Mittal, D. (2025). Artificial Intelligence in the Energy Sector: Enhancing Boiler Performance with Advanced Thermal Spray Coatings. i-manager’s Journal on Mechanical Engineering, 15(3), 56-61.

Abstract

The Energy Sector is experiencing a critical change with the integration of AI and progressed materials. This paper investigates the part of AI in upgrading the execution of evaporator businesses, especially in thermal power plants. Different thermal spray coatings utilized in evaporator applications, such as NiCrAlY and CoNiCrAlY, are examined for their benefits in enhancing erosion resistance, wear resistance, and overall effectiveness. The potential of AI in optimizing kettle operations, foreseeing support needs, and reducing energy utilization is also analyzed. By integrating AI with advanced thermal spray coatings in the energy sector, we can achieve higher efficiency, lower emissions, and greater sustainability.