Research on Multi-Source Dynamic Stress Data Analysis and Visualization Software for Structural Life Assessment

Dynamic stress data are essential for evaluating structural fatigue life. To address the challenges of complex test data formats, low data reading efficiency, and insufficient visualization, this study systematically analyzes the .raw and .sie file formats from IMC and HBM data acquisition systems and proposes a unified parsing approach. A lightweight .dac format is designed, featuring a “single-channel–single-file” storage strategy that enables rapid, independent retrieval of specific channels and seamless cross-platform sharing, effectively eliminating the inefficiency of the .sie format caused by multi-channel coupling. Based on Python v3.11, an automated format conversion tool and a PyQt5-based visualization platform are developed, integrating graphical plotting, interactive operations, and fatigue strength evaluation functions. The platform supports stress feature extraction, rainflow counting, Goodman correction, and full life-cycle fatigue damage assessment based on the Palmgren–Miner rule. Experimental results demonstrate that the proposed system accurately reproduces both time- and frequency-domain features, with equivalent stress deviations within 2% of nCode results, and achieves a 7–8× improvement in file loading speed compared with the original format. Furthermore, multi-channel scalability tests confirm a linear increase in conversion time (R2 > 0.98) and stable throughput across datasets up to 10.20 GB, demonstrating strong performance consistency for large-scale engineering data. The proposed approach establishes a reliable data foundation and efficient analytical tool for fatigue life assessment of structures under complex operating conditions.