Lightweight Structural Design of Conveyor Support Frame Using Hybrid Composite Materials

Abstract

Industrial conveyor systems rely heavily on steel support frames, which are robust but contribute significantly to overall system weight, energy consumption, and maintenance requirements. This research proposes a lightweight hybrid composite conveyor support frame utilizing a combination of carbon fiber and glass fiber reinforced polymers (CFRP/GFRP). The study focuses on structural optimization, finite element analysis (FEA), and experimental validation of a scaled frame prototype. Static, dynamic, and fatigue loading conditions typical of industrial conveyor operations are considered. Topology optimization and laminate stacking sequence design are employed to minimize weight while maintaining required stiffness and natural frequencies outside operational excitation ranges. The results demonstrate that the hybrid composite frame achieves a weight reduction of 40–50% while maintaining mechanical performance comparable to conventional steel frames. This research highlights the potential of hybrid composites for sustainable, energy-efficient industrial conveyor structures.