Abstract Lifting structures are critical components in the automotive industry, yet their excessive weight and bulk often impede mobility and ease of use. This paper presents a comprehensive study on the structural optimization of a scissor lift, focusing on the topological redesign of its lever. The primary objective is to achieve significant mass reduction while preserving structural integrity, load-bearing capacity, and safety. The core hypothesis is that strategic topological modifications can induce favorable stress redistribution, leading to material savings without compromising safety margins. The research methodology, implemented in the spring of 2024, was based on numerical modeling using the Finite Element Method (FEM) in Ansys Workbench. Numerical analysis of the base lever identified a maximum equivalent stress of 152 MPa, corresponding to a safety factor of 2.27. The proposed optimizations yielded a new lever topology that reduces the component’s mass by 39% (to 35 kg) while maintaining a high safety factor of 1.52 under a maximum stress of 226.5 MPa. The results confirm that the proposed design approach successfully enhances the lift’s performance-to-weight ratio, offering a viable solution for developing more efficient and portable automotive lifting equipment.
Bembenek et al. (Thu,) studied this question.