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LIGHTWEIGHT DESIGN OF FORKLIFT TRUCK BOOM CROSS-SECTION BASED ON MULTI-LEVEL OPTIMISATION.

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Title: LIGHTWEIGHT DESIGN OF FORKLIFT TRUCK BOOM CROSS-SECTION BASED ON MULTI-LEVEL OPTIMISATION.
Authors: Fang, Zhanpeng1,2, Zhao, Liukai1,2, Xiao, Yanqiu1,2 xiaoyanqiu@zzuli.edu.cn, Qi, Jiaqi1,2, Cui, Guangzhen1,3, Jia, Lianhui1,4, Xiao, Wei1,4
Source: Transactions of FAMENA. 2026, Vol. 50 Issue 2, p51-72. 22p.
Subjects: Structural optimization, Forklift trucks, Optimization algorithms, Multidisciplinary design optimization, Parametric modeling, Genetic algorithms, Structural components
Abstract: To reduce the material consumption of the telescopic boom of forklift trucks, a multilevel optimisation lightweight design approach for the boom is proposed. Based on actual loading conditions, a mechanical model of the boom cross-section is established, and the design is optimised through topology optimisation. By analysing the impact of element size, volume fraction, and threshold values on the performance of the telescopic boom's cross-section, the optimal topology of its configuration is obtained. The parametric model of the boom is reconstructed based on the topology optimisation result. With the minimisation of the boom mass as the objective, and both stress and deformation as constraints, the cross-sectional parameters of the boom are optimised. The design variables are sampled by the Optimal Space-Filling (OSF) design method, and the Kriging surrogate model is used to construct a high-precision model, thereby enhancing computational efficiency and ensuring accuracy. The Multi-Objective Genetic Algorithm (MOGA) is used to solve the optimisation model and identify the optimal solution. Upon validation, the optimised boom not only reduces the mass by 8.44%, but also improves its torsional stiffness, effectively reduces the material usage, and has important guiding significance for the lightweight design of telescopic booms. [ABSTRACT FROM AUTHOR]
Copyright of Transactions of FAMENA is the property of Faculty of Mechanical Engineering and Naval Architecture, University of Zegreb and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)
Database: Engineering Source
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DbLabel: Engineering Source
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PubType: Academic Journal
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  Data: LIGHTWEIGHT DESIGN OF FORKLIFT TRUCK BOOM CROSS-SECTION BASED ON MULTI-LEVEL OPTIMISATION.
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  Data: <searchLink fieldCode="AR" term="%22Fang%2C+Zhanpeng%22">Fang, Zhanpeng</searchLink><relatesTo>1,2</relatesTo><br /><searchLink fieldCode="AR" term="%22Zhao%2C+Liukai%22">Zhao, Liukai</searchLink><relatesTo>1,2</relatesTo><br /><searchLink fieldCode="AR" term="%22Xiao%2C+Yanqiu%22">Xiao, Yanqiu</searchLink><relatesTo>1,2</relatesTo><i> xiaoyanqiu@zzuli.edu.cn</i><br /><searchLink fieldCode="AR" term="%22Qi%2C+Jiaqi%22">Qi, Jiaqi</searchLink><relatesTo>1,2</relatesTo><br /><searchLink fieldCode="AR" term="%22Cui%2C+Guangzhen%22">Cui, Guangzhen</searchLink><relatesTo>1,3</relatesTo><br /><searchLink fieldCode="AR" term="%22Jia%2C+Lianhui%22">Jia, Lianhui</searchLink><relatesTo>1,4</relatesTo><br /><searchLink fieldCode="AR" term="%22Xiao%2C+Wei%22">Xiao, Wei</searchLink><relatesTo>1,4</relatesTo>
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  Data: <searchLink fieldCode="JN" term="%22Transactions+of+FAMENA%22">Transactions of FAMENA</searchLink>. 2026, Vol. 50 Issue 2, p51-72. 22p.
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  Data: <searchLink fieldCode="DE" term="%22Structural+optimization%22">Structural optimization</searchLink><br /><searchLink fieldCode="DE" term="%22Forklift+trucks%22">Forklift trucks</searchLink><br /><searchLink fieldCode="DE" term="%22Optimization+algorithms%22">Optimization algorithms</searchLink><br /><searchLink fieldCode="DE" term="%22Multidisciplinary+design+optimization%22">Multidisciplinary design optimization</searchLink><br /><searchLink fieldCode="DE" term="%22Parametric+modeling%22">Parametric modeling</searchLink><br /><searchLink fieldCode="DE" term="%22Genetic+algorithms%22">Genetic algorithms</searchLink><br /><searchLink fieldCode="DE" term="%22Structural+components%22">Structural components</searchLink>
– Name: Abstract
  Label: Abstract
  Group: Ab
  Data: To reduce the material consumption of the telescopic boom of forklift trucks, a multilevel optimisation lightweight design approach for the boom is proposed. Based on actual loading conditions, a mechanical model of the boom cross-section is established, and the design is optimised through topology optimisation. By analysing the impact of element size, volume fraction, and threshold values on the performance of the telescopic boom's cross-section, the optimal topology of its configuration is obtained. The parametric model of the boom is reconstructed based on the topology optimisation result. With the minimisation of the boom mass as the objective, and both stress and deformation as constraints, the cross-sectional parameters of the boom are optimised. The design variables are sampled by the Optimal Space-Filling (OSF) design method, and the Kriging surrogate model is used to construct a high-precision model, thereby enhancing computational efficiency and ensuring accuracy. The Multi-Objective Genetic Algorithm (MOGA) is used to solve the optimisation model and identify the optimal solution. Upon validation, the optimised boom not only reduces the mass by 8.44%, but also improves its torsional stiffness, effectively reduces the material usage, and has important guiding significance for the lightweight design of telescopic booms. [ABSTRACT FROM AUTHOR]
– Name: AbstractSuppliedCopyright
  Label:
  Group: Ab
  Data: <i>Copyright of Transactions of FAMENA is the property of Faculty of Mechanical Engineering and Naval Architecture, University of Zegreb and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract.</i> (Copyright applies to all Abstracts.)
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        Value: 10.21278/TOF.502075425
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        Text: English
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        Type: general
      – SubjectFull: Optimization algorithms
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      – SubjectFull: Multidisciplinary design optimization
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      – SubjectFull: Genetic algorithms
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      – SubjectFull: Structural components
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      – TitleFull: LIGHTWEIGHT DESIGN OF FORKLIFT TRUCK BOOM CROSS-SECTION BASED ON MULTI-LEVEL OPTIMISATION.
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            – D: 01
              M: 04
              Text: 2026
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