Truss structure optimization of heavy-duty escalators via finite element analysis

To adapt to the characteristics of high load and long-term operation of heavy-duty escalators, traditional trusses often adopt redundant structural designs to meet higher safety and reliability requirements, resulting in increased self-weight and higher manufacturing costs. Therefore, achieving the redesign of truss structures without compromising mechanical performance is necessary. In this work, static analysis of the heavy-duty escalator truss was conducted using Abaqus finite element simulation software. The influencing factors of truss deflection and weight were analyzed, as well as the effect of truss structure composition, distribution, and dimensions on truss performance, in order to obtain an optimized truss structure with the best mechanical performance. Subsequently, a three-dimensional model of the truss was established and modified based on the actual truss structure. The correctness of the model was verified through experimental results of an actual heavy-duty escalator truss project. Utilizing this model, the goal of reducing deflection and weight under the most economical conditions was pursued, and an economic analysis of the chords was conducted to propose the strengthening and weakening strategies. This work can serve as a guide for the design of heavy-duty escalator truss structures, helping to enhance the rationality and reliability of truss structures, reduce development costs, and improve economic benefits.