2010 International Conference on Digital Manufacturing & Automation

APDL language-based optimization of tower crane

Song Shijun, Li Lei, Wang Jiyong, Mao Ruinian
Shandong Jian Zhu University, Jinan, Shandong, 250101, China.
shandongsongshj@126.com
Shandong Jian Zhu University, Jinan, Shandong, 250101, China.
Lilei1984lilei@163.com
Shandong Jian Zhu University, Jinan, Shandong, 250101, China.
wjyhjn@163.com
Shandong Foryou Company, Jinan, Shandong, 250101, China
h133566@sina.com
and crane boom, there are lots of slender structures, even if
the stress of each element is in the allowable range,
stabilityof the tower crane may not meet the requirements.
In order to solve the two shortcomings above, the
optimization program of this paper makes some
improvements in basis of traditional optimization methods
and approaches a new optimization design method to make
optimization of tower crane more rapid, and constraints of
which is more comprehensive.
This paper introduces the general optimization procedure
of OPT module. An optimization model and program of
tower crane steel structure is introduced , which combines
FEA and stability theory. The key technologies are stressly
elaborated. Finally an optimization example is taken to
illustrate its effectiveness.

AbstractOptimization design of tower crane steel structure

is very important for design technique development of tower
crane. This paper proposes a kind of parametric optimization
model based on Ansys OPT, combined with finite element
analysis (FEA) and overall stability theory. The tower body is
taken as an example to introduce the building process and the
program structure of the parametric optimization model. The
combination of calibrating of overall stability and single-limb
stability and FEA and OPT is realized through extracting
some paramete from FEA results, such as weight and axial
force, etc. The realization of the key technology is discussed. A
rapid optimization design of tower body is realized by
developing corresponding program using ansys parametric
design language (APDL). It has a referenced meaning for other
optimization design of steel structure.
Keywords-Optimization; Finite element analysis (FEA); Ansys;
Tower crane; Stability; Tower body

I.

II.

A. Optimization steps of OPT

The optimization design process of OPT typically
includes the following:

INTRODUCTION

With development of high-rise buildings in urban

construction, height of buildings become more and more
higher, tower crane is widely used as vertical transportation
machinery in high-rise building construction. Tower crane is
all made by space truss structure, so it is particularly
important for optimization of tower crane to ensure the
structure not only safe but also saving steel. But it is difficult
to calculate stress state of each beam element with traditional
calculation methods, as a result, the optimization is not
accurate. So it is necessary to use finite element means to
optimize the structure, which can save more materials in the
situation of ensuring sufficient strength of each elment in the
structure.
OPT module is the optimization module of Ansys
software.
APDL is a parametric design language in Ansys software,
parametric modeling can be realized in which ,and provide a
pre-processing platform for optimization of the OPT module.
However, parametric modeling is inefficient, which takes
2 or 3 days at least.
In addition, traditional OPT optimization can only
control stress of each element and deflection of each node,
which can not control overal and local stability of truss
structure in allowable range. However, like as tower body
978-0-7695-4286-7/10 $26.00 2010 IEEE
DOI 10.1109/ICDMA.2010.200

INTRODUCTION OF OPT

Figure 1. The typical optimization design process of OPT

B. The concept of design variables and state variables in

OPT
Design variables: Design variables are independent
variables, and the optimization is achieved by changing
value of design variables. The design variables have both
upper and lower limits ,which define range of themselves.
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State variables: State variables are used for constraining

a design. As "dependent variables", the state variable is a
function of design variables, it may have both upper and
lower limits, or only one of the two limits.
C. This interpretation of the optimization variables and
the Non-optimization variable in this paper
Optimization variables: The optimization variables are
different from the design variables in OPT. Value of design
variables in this optimization model are changed by OPT,
which refers to the areas of each cross-sectionwhile the
optimization variables refers to all the cross-section
characteristics, including area, moment of inertia and
flexural modulus, etc. the optimization variables are changed
by the optimization program in this paper, which can lookup table according to the current value of the areas.
Non-optimization variables: Non-optimization variables
refer to invariable values in optimization process, including
shape size, material properties, upper and lower limits of
state variables, loads, etc.
III.

Figure 3. Structure parameters of tower body

Optimization variables are section characteristic

parameters of section 1~8 in Figure 3, whose areas are A1-A8,
and the section characteristic parameter here is a vector
whose elements contain area ,moment of inertia, bending
modulus, that is: Xi = (Ai, Iyi, Izi, Wyi, Wzi,), i = 1~8.
constraints:
maximum stress constraints: maxi<[i], i=1~8
maximum deflection constraints: dmax<[d]
overall stability constraints:
V j1 d [V j1 ] , V j 2 d [V j 2 ]

OPTIMIZATION PROGRAM AND OPTIMIZATION MODEL

OF TOWER BODY

A. Structure of optimization program

Structure of optimization program is shown in Figure 2.

V j1 and V j 2 Refers

to the overall stability stress of the

entire cross-section 1 (the connection section

of masts and foundational masts) and the entire
cross-section 2 (the section on the tower root) .
Single-limb stability constraints:

Vi
Figure 2. Structure of optimization program

Ni
d [V i ] , i=18
AiM i

NiThe largest axial force of single-limb section 1~8.

Ai The cross-sectional area of single-limb section
1~8.
objective function:

Users input non-design variables such as load, material,

upper and lower limits of state variables and structural
parameters through man-machine interface. According to
these non-design variables, an analysis file is generated by
FEA caculating, overall and single-limb stability caculating
though looking-up profiled bar table, wind reduction factor
table and stability factor table. Finally, analying file is called
by OPT module to carry out the optimization and generate
analying results.

G=min{

i=1n}

giThe weight of various parts of the tower body.

C. The process of the optimization program
The process of the optimization program is shown in
Figure 4.

B. Optimization model
This model is applicable to optimization of tower body
with K shaped web rod. Because non-optimization
variables in the optimization model are set by users, the
optimization program can be widly used. The Parametric
in the "Parametric optimization model" refers to the
parameterization of non-optimization variables.
Optimization variables

Figure 4. The process of the optimization program

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Parametric modeling, solving, extraction and

parameterization of results, calculation of stability and
generation of analysis file contains the following process
steps shown in Figure 5.

Firstly, process of computation should be combined, as

shown in Figure 6. As the intermediate results, the results
from FEA method such as axial force and weight are
respectively used to calculate the overall stability stress and
the single limb stability stress to make the stability
calculation more accurate.
Secondly, finite element results and stability stress
control constraints together as state variables.
C. Realization of parameterization of non-optimization
variables
Non-optimal variables are fixed value on a particular
optimization design, and they do not change their values in
the optimization process; But for different optimization
design, values of which are generally different. These nonoptimized variables geted from user interface are used as
basis of finite element modeling and analysis and stability
caculation. Therefore, in a particular optimization design,
when users import these non-optimal variables, the
optimization design can be carried out according to users
needs . In this way, an optimization design that needs 1~2
days can be finished in 3~4 minutes.
V.

Figure 5. The process of generation of the analysis file

IV.

KEY TECHNOLOGIES

A.

Realization of optimization variables discretization

Discretization of optimization variables refers to that
cross-section characteristics of beam element change in a
number of discrete points, which represent cross-section
characteristic of standard section given in profiled bar table.
Its realization is based on the current value of the area
(design variables). The program find the right profile from
the profiled bar table, then all the cross-section
characteristics of the right profile parameters (optimization
variables) are extracted. Then, discretization of optimization
variables is realized.
B.

OPTIMIZATION EXAMPLES

Taking tower body of the PT125 tower crane from

Shandong Foryou company as an example, this optimization
program is used to optimize the tower body of PT125, and
the results are shown in Table 1.
As shown in Table 1, overall stability , single-limb
stability and rigidity is enhanced, and maximum stress tends
to smooth after optimization. Further more, the weight has
been reduced by 11.4%. This example illustrate that the
effect of optimization is very obvious.
VI.

CONCLUSIONS

The modularization of optimization of tower body is

realized through realization of parameterization of nonoptimized variables. Combination of FEA and overall
stability theory is realized through some finite element
results being borrowed in calculation of stability to make
calculation of stability stress more accurate. Constraints are
maked more comprehensive and reasonable through
maximum stress and stability stress being constrained
together as state variables. Optimization variables are
dispersed into standard sections that meet national standard
through dispersion of optimization variables, making
optimization results closer to reality.
The next step is to develop optimization program of
other parts of the tower crane.

The realization of the combination of stability check

and finite element method

ACKNOWLEDGMENTS
This study was supported by National Natural Science
Foundation of China (50775132) and a major research
program of Shandong Province (200 890 101 043).
Figure 6. Combination of stability check and finite element method

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Table 1 Optimization results

A1

section

A2

A3

A4

A5

A6

A7

A8

897

54x5

54x5

2-L12510

837

545

545

2-L12512

897

304

382.5

382.5

163

124.4

23.8

71.5

134

125.4

38.6

79.3

159.1

130.6

21.9

65.9

142.4

136.3

48.5

76.2

164

94

159.5

104

159.6

93.1

161.7

84.4

Section before optimization 2-L12512

Section after optimization
Maximum stress before
optimization (MPa)
Maximum stress after
optimization (MPa)
single-limb stability stress
before optimization (MPa)
single-limb stability stress
after optimization (MPa)
overallstability stress of
section1 (MPa)
overallstability stress of
section2 (MPa)
maximum deflection (mm)

Before optimization
198
Before optimization
190
Before optimization
484.3

weight before optimization

(kg)
weight after optimization
(kg)
percentage of reduction in
weight

After optimization
199.4
After optimization
184
After optimization
482.4
137009
121376
11.4%

REFERENCES
[1]
[2]
[3]
[4]

382.5 2-L12510 1085.5

Shang Yuejin, Finite element theory and Ansys application guide

Tower crane design standards (GB/T13752-1992).
Crane design standards(GB/T3811-2008)
Hou Jiabao, Optimized design of jib of derrick tower crane .
Construction Mechanization, 2006.11. (in Chinese).

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