Diseño y simulación de un sistema de rotación para volteo de compost en una máquina agrícola con capacidad de procesamiento de 200 m3/h para la Comunidad San Francisco Javier

Abstract

This thesis develops the design and mechanical simulation of a compost turning rotor for a bridge-type turning machine with a processing capacity of 200 m³/h, aimed at strengthening sustainable agricultural production systems in the rural community of San Francisco Javier, Bolívar province, Ecuador. The study arises in response to the high generation of organic solid waste in the country and the limited adoption of sustainable utilization technologies, particularly in rural areas where composting represents a viable technical alternative for the management of biodegradable waste. The research is based on an analysis of the operational problem associated with the insufficient capacity of the existing machinery, which operates at 220 m³/h and does not meet the growing demand for organic compost from the populations of Salinas, Simiatug, and Santiago. In this context, the incorporation of a new turning system is proposed which, operating in conjunction with the current equipment, will allow a total theoretical capacity of 420 m³/h to be achieved, optimizing processing time, operational continuity, and the use of organic material. From an engineering perspective, the mechanical dimensions of the agitator rotor are determined based on actual operating conditions, the bulk density of the compost, structural robustness criteria, low energy requirements, and local manufacturing feasibility. A horizontal shaft rotor with a mixed configuration of straight blades and L-shaped angled blades is selected, achieving a balance between turning efficiency, material lifting, and mechanical strength, especially under conditions of high humidity and load. The proposed design is validated through analytical calculations and structural simulations, using tools such as Finite Element Analysis (FEA) software. The results show that the software tends to overestimate safety factors, particularly in rigid components, while FEA provides more conservative values that are representative of actual behavior in critical elements such as blades, shaft, and complete rotor. The rotor has an adequate safety factor, confirming compliance with structural criteria and the mechanical viability of the design. Finally, the work provides detailed technical documentation that supports the design and simulation process, establishing a solid foundation for future stages of manufacturing, experimental validation, and implementation, contributing to the development of sustainable technological solutions, the strengthening of organic agriculture, and the efficient use of organic solid waste in community contexts.