Designing Lightweight Giants: Buckling-Constrained Optimization of Transmission Line Towers
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Increased decentralized power generation heightens the need for efficient transmission infrastructure worldwide, resulting in large investments regarding the energy grid. Transmission line towers remain the most cost effective solution for long distance power transfer, yet many established designs predate modern computational optimization. This study applies contemporary topology optimization to the crossarm, traverse, of commonly used 380 kV towers to reduce the material costs of modern power grids. In this paper, steel structures designed to Eurocode provisions are analyzed, while restricting cross-sections to L-profiles, as transmission line towers are predominantly built from these profiles. First, the canonical cantilever with a point load is analyzed to relate material usage to compliance (sum of elastic strain energy) [1] across various designs, including classical Michell structures. The results indicate that the buckling constraint dominates the structural design. Although, conventional civil engineer solutions outperform those designed by the topology optimization regarding the material usage, they exhibit higher axial forces. Their greater material usage primarily stems from unstressed members that are absent in minimumcompliance designs. In the second analysis, topology-optimized structures are generated via established compliance minimization [1] and mapped to truss realizations. Comparing these to existing transmission tower crossarm designs. Consistent with the first study, the built designs outperform the compliance-based layouts while showing higher internal stresses. Finally, unloaded beams are inserted into the topology-optimized design and the resulting structure is compared with the built design. Results show that introducing strategically placed, nominally unstressed ties between compression subassemblies improves buckling resistance and therefore lowers mass, whereas compliance only optimized trusses without such ties underperform compared with standard practice. The proposed crossarm achieves a 16% reduction in material relative to a wellestablished built and optimized reference design.
