Topology Optimization of Leg Structures for Construction Robots Based on Variable Density Method

In complex terrain construction environments, there are high demands for robots to achieve both high payload capacity and mobility flexibility. As the key load-bearing component, the optimization of robotic leg structures is of particular importance. Therefore, this study focuses on the optimization of leg structures for construction robots, proposing a topology optimization strategy based on the SIMP (Solid Isotropic Microstructures with Penalization) variable density method along with a structural re-design approach. The design performance is comprehensively validated through finite element analysis using ANSYS. First, static and modal analyses are conducted to evaluate the rationality of the initial design. Then, topology optimization using the SIMP-based variable density method is applied to the femur section, which accounts for the largest proportion of the leg's weight. Based on iterative calculations, the femur undergoes secondary structural reconstruction. After optimization, the mass of the femur is reduced by 19.45\%, and the overall leg mass decreases by 7.92\%, achieving the goal of lightweight design. Finally, static and modal analyses are conducted on the reconstructed leg. The results demonstrate that the optimized leg still meets structural performance requirements, validating the feasibility of lightweight design. This research provides robust theoretical and technical support for lightweight construction robot design and lays a foundation for their efficient operation in complex construction environments.