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

Öz

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.

Anahtar Kelimeler

• Belt conveyor
• Bracket
• Topology optimisation
• Structural analysis

Topoloji Optimizasyonu ile Bantlı Konveyör Braketinin Yapısal Analizi ve Tasarım Geliştirilmesi

Öz

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.

Anahtar Kelimeler

• Bantlı konveyör
• Braket
• Topoloji optimizasyonu
• Yapısal analiz

Kaynakça

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