Research On Real-time Monitoring Of Mechanical States Of Crane Main Beams Based On Digital Twin Technology

As a type of material handling machinery,crane equipment can effectively improve production efficiency,reduce labor intensity,and achieve automated production,and has been widely used in various fields such as engineering construction,logistics warehousing,and ship loading and unloading.However,due to the complex factors such as environment and heavy loads during operation,cranes are prone to various malfunctions,so the safety and reliability requirements for cranes are becoming increasingly high.Among them,the main beam of the crane is an important component that bears the weight and inertia force of the lifted object,and the monitoring of its mechanical state is of great significance for the safe production of the crane.In the past,the monitoring of the main beam mainly relied on manual inspections and empirical judgments,resulting in low monitoring efficiency and inaccurate results.With the development and application of digital twin technology,it has become possible to apply it to the monitoring of the main beam of the crane.Digital twin technology(DT)is a method of digitizing physical systems driven by intelligent sensing systems.By establishing a digital twin model of the main beam structure of the crane,its mechanical state can be monitored and analyzed comprehensively in a virtual environment,effectively avoiding the huge property losses and safety risks caused by the failure of vulnerable structures,and providing strong support for the safe production of cranes.This paper applies digital twin technology to the solution of mechanical properties of the main beam of a crane,proposes a digital twin method for monitoring the mechanical state of a bridge crane main beam,and presents solutions to key technologies in the construction process of the digital twin body.The main research content is as follows.(1)In order to meet the requirement of using measured data to drive the digital twin of the crane,a wireless strain monitoring scheme is proposed based on traditional strain gauging techniques.The data is processed and converted into analog signals by the STC12C5410 AD single-chip microcomputer and transmitted to the PC terminal via Lo Ra long-distance wireless transmission technology.This provides key strain monitoring of critical force points for safe crane operation and provides measured strain input for subsequent real load sensing of the crane beam.(2)In order to address the problem of inaccurate load sensing in the crane digital twin,a load inversion technique based on measured strain is studied in depth.Different loading experiments are designed for the crane trolley in different positions to measure the strain response at each measurement point and obtain the linear relationship between strain response and actual load.A load sensing model is generated with measured strain response as input and load history as output in the ANSYS Twin Builder environment.(3)In order to construct a digital twin model for a crane,ANSYS Mechanical was first used to establish a finite element analysis model of the main beam.To achieve fast analysis of mechanical performance,the model order reduction technique and its principles were thoroughly studied,and the existing full-order finite element model was reduced to generate stress and deformation reduced-order models.Finally,in the ANSYS Twin Builder environment,the load identification model and the reduced-order model were connected,and the reserved strain data input interface was connected to the PC serial port for data transmission,and wireless strain monitoring system data was read and the mechanical state calculation results were visually displayed.Ultimately,a mechanical state monitoring system for the crane main beam was achieved in the Twin Builder environment,with measured strain data as input and the global mechanical state response of the structure as output.