Topology Optimization–Based Analysis and Redesign of a Belt Conveyor Bracket

Abstract

This study aims to redesign a bracket that connects rollers to the chassis in belt conveyors, which are widely used in continuous transport systems, to achieve a lighter and more cost-effective structure while maintaining comparable structural strength, and to present this design process through a systematic approach. A three-dimensional solid model was created based on the existing design of a commercially used bracket component. The loads acting on the solid model were calculated using analytical methods. Boundary conditions were defined for the analysis, and static analyses were performed using the finite element method. Subsequently, density-based topology optimization was carried out using the Solid Isotropic Material with Penalization (SIMP) approach. During the optimization process, material was removed from structurally non-critical regions to obtain a new design, and the optimized model was reanalysed under the same loading conditions. The results indicate an 18% increase in total deformation and a limited increase in von Mises stress. Despite these increases, the structural strength was preserved while the total mass was reduced by approximately 35%. Overall, this study proposes a topology optimization process for structural components used in transport systems and presents a new design methodology that balances manufacturability and performance.

Keywords

• Belt conveyor
• Bracket
• Topology optimisation
• Structural analysis

Supporting Institution

TAİ - LIFT UP++, İTÜ BAP

Project Number

İTÜ BAP: MDKB-2025-47274, TUSAŞ LIFT UP ++

Ethical Statement

This study was conducted in accordance with research and publication ethics.

Thanks

This work was supported by Scientific Research Projects Department of Istanbul Technical University, Project No: MDKB-2025-47274. M. Raşit Karakoca supported by Turkish Aerospace Industries Inc. (TUSAŞ) within the scope of the LIFT UP++ Industry-Oriented Doctoral Research Program.

Topoloji Optimizasyonu ile Bantlı Konveyör Braketinin Yapısal Analizi ve Tasarım Geliştirilmesi

Abstract

Bu çalışma, sürekli transport sistemlerinden bantlı konveyörlerde, silindirleri şasiye bağlayan bir braketi, yakın yapısal mukavemet değerlerinde, daha hafif ve daha ekonomik bir yapıda tekrar tasarlamayı ve bu tasarım sürecini sistematik bir yaklaşımla sunmayı amaçlamaktadır. Sahada kullanılan, ticari bir braket parçasının halihazırdaki tasarımı ele alınarak üç boyutlu katı model yaratılmıştır. Katı modele etkiyen yükler analitik yöntemlerle hesaplanmıştır. Analiz için sınır koşulları tanımlanmış ve sonlu elemanlar metodu ile statik analizler gerçekleştirilmiştir. Ardından Solid Isotropic Material with Penalization (SIMP) yaklaşımı kullanılarak yoğunluk tabanlı topoloji optimizasyonu yapılmıştır. Optimizasyon süreci sırasında, yeni bir tasarım elde etmek için yapısal olarak kritik olmayan alanlardan malzeme çıkarılmış ve daha sonra aynı yükleme koşulları altında; model yeniden analiz edilmiştir. Sonuçlar, en büyük toplam deformasyonda %18 oranında bir artış ve von-Mises gerilmesinde ihmal edilebilir bir artış göstermiştir. Bu artışlara rağmen, yapının mukavemeti korunurken, toplam kütlede yaklaşık %35 oranında azalmıştır. Genel olarak, bu çalışma transport sistemlerinde kullanılan yapısal elemanlar için bir topoloji optimizasyonu prosesi önermekte ve üretilebilirlik ve performansı dengeleyerek yeni bir tasarım metodolojisi sunmaktadır.

Keywords

• Bantlı konveyör
• Braket
• Topoloji optimizasyonu
• Yapısal analiz

Supporting Institution

TUSAŞ - LiftUP++, İTÜ BAP

Project Number

İTÜ BAP: MDKB-2025-47274, TUSAŞ LIFT UP ++

Ethical Statement

Bu çalışmada araştırma ve yayın etiğine uyulmuştur.

Thanks

Bu çalışma İstanbul Teknik Üniversitesi Bilimsel Araştırma Projeleri Koordinasyon Birimince Desteklenmiştir. Proje Numarası: MDKB-2025-47274. M. Raşit Karakoca, LIFT UP++ Sanayi Odaklı Doktora Araştırma Programı kapsamında Türk Havacılık ve Uzay Sanayii A.Ş. (TUSAŞ) tarafından desteklenmektedir.

References

1. [1] R.M. Bosse, L. Silvestro, G. de M.S. Gidrão, T.L.P. Ortolan, P.M. Borges, J.J. de O. Andrade, Reliability and durability assessment of recycled aggregate concrete under chloride ingress: Design optimization and service life implications, Case Studies in Construction Materials 21 (2024) e04045. https://doi.org/10.1016/j.cscm.2024.e04045.
2. [2] L. Zhao, G. Liu, Optimization of the catalyst service life based on the coupling of reactor and heat exchanger network, Chem. Eng. Sci. 259 (2022) 117822. https://doi.org/10.1016/j.ces.2022.117822.
3. [3] M.R. Karakoca, A.E. Erdoğdu, Design of Triaxial Impact Wear Tester: Finite Element Simulation for Performance Analysis of AA6061-T6 Alloy, Tribology in Industry 47 (2025) 705–717. https://doi.org/10.24874/ti.1979.07.25.09.
4. [4] S.H. Hong, S. Bin Choi, M.Y. Jang, S.J. Kim, Integrated topology and power distribution optimization for the shipboard hybrid energy storage system via genetic algorithms and dynamic programming, Ocean Engineering 339 (2025). https://doi.org/10.1016/j.oceaneng.2025.122095.
5. [5] B. Li, S.S. Nanthakumar, Y. Pennec, B. Djafari-Rouhani, X. Zhuang, Topology optimization of phoxonic crystals for maximizing dual bandgaps using GA-SIMP method, Int. J. Mech. Sci. 300 (2025) 110359. https://doi.org/10.1016/j.ijmecsci.2025.110359.
6. [6] Z. Lei, Z. Deng, Y. Liang, G. Chen, R. Li, D. Yang, Hybrid method of SIMP and SAIP for reliability-based topology optimization considering strength failure under load uncertainty, Comput. Methods Appl. Mech. Eng. 441 (2025). https://doi.org/10.1016/j.cma.2025.117975.
7. [7] M.N. Nguyen, N. Nguyen-Thanh, S. Chen, T.Q. Bui, Multi-material topology optimization of thermoelastic structures by an ordered SIMP-based phase field model, Computers and Mathematics with Applications 186 (2025) 84–100. https://doi.org/10.1016/j.camwa.2025.03.005.
8. [8] T. Zuo, H. Han, Q. Wang, Q. Zhao, Z. Liu, An explicit topology and thickness control approach in SIMP-based topology optimization, Comput. Struct. 307 (2025). https://doi.org/10.1016/j.compstruc.2024.107631.

9. [9] W. Zhang, Y. Liu, J. Zhang, J. Li, X. Guo, S.K. Youn, Topology optimization of structures guarding against brittle fracture via peridynamics-based SIMP approach, Comput. Methods Appl. Mech. Eng. 432 (2024). https://doi.org/10.1016/j.cma.2024.117438.
10. [10] L. Hrabovsky, V. Molnar, G. Fedorko, J. Tkac, K. Frydrysek, Experimental determination of force acting on a sandwich conveyor’s pressure roller in transport of bulk materials for the needs of failure analysis, Measurement (Lond). 202 (2022). https://doi.org/10.1016/j.measurement.2022.111832.
11. [11] İ. Gerdemeli, C.E. İmrak, M.K. Kesikçi, Sürekli Transport Sistemleri, Birsen Yayınevi, İstanbul., 2005.
12. [12] H. Gilvari, C.H.H. van Battum, R. Farnish, Y. Pang, W. de Jong, D.L. Schott, Fragmentation of fuel pellets during transport via a belt conveyor: A design of experiment study, Particuology 66 (2022) 29–37. https://doi.org/10.1016/j.partic.2021.08.007.
13. [13] L. Hrabovsky, G. Fedorko, V. Molnar, Measurement of the bulk material distribution length on a conveyor belt surface guided on a three-roller idler housing, Measurement (Lond). 253 (2025). https://doi.org/10.1016/j.measurement.2025.117849.
14. [14] M. Bajda, R. Krol, Experimental Tests of Selected Constituents of Movement Resistance of the Belt Conveyors Used in the Underground Mining, Procedia Earth and Planetary Science 15 (2015) 702–711. https://doi.org/10.1016/j.proeps.2015.08.098.
15. [15] V. Molnár, G. Fedorko, B. Stehlíková, P. Michalik, M. Weiszer, A regression model for prediction of pipe conveyor belt contact forces on idler rolls, Measurement (Lond). 46 (2013) 3910–3917. https://doi.org/10.1016/j.measurement.2013.07.045.
16. [16] T. Su, T. He, R. Yang, M. Li, Topology optimization and lightweight design of stamping dies for forming automobile panels, International Journal of Advanced Manufacturing Technology 121 (2022) 4691–4702. https://doi.org/10.1007/s00170-022-09683-2.
17. [17] W. Zhang, W. Zhong, X. Guo, An explicit length scale control approach in SIMP-based topology optimization, Comput. Methods Appl. Mech. Eng. 282 (2014) 71–86. https://doi.org/10.1016/j.cma.2014.08.027.
18. [18] M. Zhou, Y. Liu, Z. Lin, Topology optimization of thermal conductive support structures for laser additive manufacturing, Comput. Methods Appl. Mech. Eng. 353 (2019) 24–43. https://doi.org/10.1016/j.cma.2019.03.054.
19. [19] R. Su, S. Tangaramvong, C. Song, Automatic Image-Based SBFE-BESO Approach for Topology Structural Optimization, Int. J. Mech. Sci. 263 (2024). https://doi.org/10.1016/j.ijmecsci.2023.108773.
20. [20] Y.L. Yap, W. Toh, A. Giam, F.R. Yong, K.I. Chan, J.W.S. Tay, S.S. Teong, R. Lin, T.Y. Ng, Topology optimization and 3D printing of micro-drone: Numerical design with experimental testing, Int. J. Mech. Sci. 237 (2023). https://doi.org/10.1016/j.ijmecsci.2022.107771.
21. [21] R. Ramadani, S. Pal, M. Kegl, J. Predan, I. Drstvenšek, S. Pehan, A. Belšak, Topology optimization and additive manufacturing in producing lightweight and low vibration gear body, International Journal of Advanced Manufacturing Technology 113 (2021) 3389–3399. https://doi.org/10.1007/s00170-021-06841-w.
22. [22] N. Ichihara, M. Ueda, 3D-printed high-toughness composite structures by anisotropic topology optimization, Compos. B Eng. 253 (2023) 110572. https://doi.org/10.1016/j.compositesb.2023.110572.
23. [23] F.N. Şen, M.K. Can, Recent Reviews on Topology Optimization, Gazi Üniversitesi Fen Bilimleri Dergisi Part C: Tasarım ve Teknoloji 13 (2025) 1268–1285. https://doi.org/10.29109/gujsc.1761253.
24. [24] B. Çalik, G. Uzun, Metal Eklemeli İmalatta Topoloji Optimizasyonu Uygulamaları, Gazi Üniversitesi Fen Bilimleri Dergisi Part C: Tasarım ve Teknoloji 12 (2024) 832–844. https://doi.org/10.29109/gujsc.1542929.
25. [25] A.F. Yılmaz, Topoloji Optimizasyonu ile Gemi Çift Dip Konstrüksiyonu Dolu Döşek Tasarım İyileştirilmesi, Gazi Üniversitesi Fen Bilimleri Dergisi Part C: Tasarım ve Teknoloji 13 (2025) 763–776. https://doi.org/10.29109/gujsc.1663786.
26. [26] M. Eryıldız, B. Bay, Design and Analysis of a Topology-Optimized Quadcopter Drone Frame, Gazi Üniversitesi Fen Bilimleri Dergisi Part C: Tasarım ve Teknoloji 12 (2024) 427–437. https://doi.org/10.29109/gujsc.1316791.
27. [27] U. YAMAN, Topoloji Optimizasyonu Yapılmış Parçaların 3B Yazıcılar ile Doğrudan Üretilmesi, Gazi Üniversitesi Fen Bilimleri Dergisi Part C: Tasarım ve Teknoloji 7 (2019) 236–244. https://doi.org/10.29109/gujsc.491244.
28. [28] A. Candas, E. Kayaoğlu, A. Candaş, E. Kayaoǧlu, FEM and Experimental Stress Analysis of a Jib Crane, in: Applied Mechanics and Materials, Trans Tech Publications, 2013: pp. 877–880. https://doi.org/10.4028/www.scientific.net/AMM.395-396.877.
29. [29] A. Sancak, A. Candaş, C.E. Imrak, Analysis and Comparison of Elevator Cabin Guide Rail Bracket Designs Under Earthquake Load, European Journal of Science and Technology 24 (2021) 60–66. https://doi.org/10.31590/ejosat.901663.
30. [30] X. Wang, S. Günay, W. Lu, Seismic analysis of the rail-counterweight system in elevators considering the stiffness of rail brackets, Advances in Structural Engineering (2020). https://doi.org/10.1177/1369433220974777.
31. [31] E. Tyflopoulos, M. Steinert, A Comparative Study of the Application of Different Commercial Software for Topology Optimization, Applied Sciences (Switzerland) 12 (2022). https://doi.org/10.3390/app12020611.
32. [32] A. Amroune, J.C. Cuillière, V. François, Automated Lofting-Based Reconstruction of CAD Models from 3D Topology Optimization Results, CAD Computer Aided Design 145 (2022). https://doi.org/10.1016/j.cad.2021.103183.
33. [33] B. Xie, X. Wu, L. Liu, Y. Zhang, Topological Design of a Hinger Bracket Based on Additive Manufacturing, Materials 16 (2023). https://doi.org/10.3390/ma16114061.