Simultaneous topology, configuration, and prestress optimization for lightweight design of modular tensegrity chain structures

Abstract

Lightweight design has emerged as a valuable research focus in tensegrity structures, gaining increasing attention across various engineering domains that prioritize weight reduction. While many existing studies have concentrated on the lightweight design of conventional tensegrity structures, relatively little attention has been paid to those derived from modular assembly. This study focuses on a specific type of modular tensegrity chain structure (TCS) and presents a comprehensive framework for its lightweight design. The proposed framework innovatively integrates three critical design aspects: prestress determination, configuration design, and topology optimization, while simultaneously accounting for various design constraints under both prestress and load states. This framework is formulated as a bilevel optimization model. Prestress optimization is first performed at the internal level and then incorporated into the external-level model for configuration design and topology optimization. Subsequently, improved hybrid algorithms are also introduced to solve the optimization problem. Three representative numerical examples are provided to validate the effectiveness of the proposed framework and solving algorithms. The results demonstrate that this comprehensive approach achieves significant mass reduction compared to single-aspect designs. The proposed framework offers a more holistic and efficient solution for lightweight TCS design, showcasing its potential for enhancing the performance and efficiency of modular tensegrity structures in engineering applications.