A Development Method for Load Adaptive Matching Digital Twin System of Bridge Cranes

Bridge cranes generally have a significant disparity between their actual service life and design life. If they are scrapped according to the design life, it is likely to result in resource wastage or pose potential safety hazards due to extended service. Existing studies have not thoroughly examined the coupling relationship among actual working conditions, structural damage, and load-matching strategies. It is difficult to achieve real-time and accurate adaptation between loads and the carrying capacity of equipment, and thus cannot effectively narrow this life gap. To this end, this paper defines a digital twin system framework for crane load adaptive matching, constructs a load adaptive matching optimization model, proposes a method for developing a digital twin system for bridge crane load adaptive matching, and builds a digital twin system platform centered on virtual-real mapping, IoT connectivity, and data interaction. Detailed experimental verification was conducted using the DQ40 kg-1.8 m-1.3 m light-duty bridge crane. The results demonstrate that this method and system can effectively achieve dynamic matching between the load and real-time carrying capacity. While ensuring the service life exceeds the design life, the difference between the two is controlled at around 3467 cycles, accounting for approximately 0.000462% of the design life. This significantly improves the equipment’s operational safety and resource utilization efficiency, breaks through the limitations of load reduction schemes formulated based on human experience under the traditional regular inspection mode, and provides a scientific load-matching decision-making basis and technical support for special equipment inspection institutions and users.