Topology Optimization and Generative Design for Weight Reduction in Palletizer Robots

The palletizing robot has captured approximately 8.5% of the industrial robot market, valued at around USD 4.13 billion, and is swiftly replacing human labor in various industrial applications. However, the high self-weight of palletizer robots has led to increased energy consumption in industries. While numerous research efforts have focused on optimizing the upper arm of these robots, limited attention has been given to the lower arm, base, and other heavy components. This study aims to reduce the self-weight of the palletizer robot by applying topology optimization and generative design principles. The optimization process, initiated for the IRB460 palletizer robot, achieved a 10.89% reduction in the robot's self-weight, from 757.47 kg to 674.94 kg. The optimized design showed improved stress distribution and maintained structural integrity, highlighting the potential for cost savings and enhanced performance in industrial applications.