Journal of Engineering Research and Reports

To meet the high requirements for accuracy and real-time performance of main girder monitoring of overhead bridge cranes in digital twin systems, this paper studies the model order reduction technology combined with digital twin to realize the rapid analysis of the mechanical performance of crane main girders. To begin with, a detailed and high-precision finite element full-order model of the crane main girder is built utilizing professional finite element analysis programs. Then, based on the model order reduction principle, Subsequently, the full-order model was order-reduced using Ansys Twin Builder, while the critical parameters dominating the mechanical behavior of the main girder were preserved. On this basis, a reduced-order model (ROM) capable of accurately characterizing the stress distribution and deformation evolution of the main girder was established. For verification, identical loads and boundary constraints were imposed on both the full-order and reduced-order models, and the computational accuracy of the ROM was validated through comparative analysis. The results demonstrate that the ROM keeps the relative errors of stress and deformation within the allowable engineering range, and the mechanical analysis duration is shortened to the second level. Accordingly, the real-time monitoring requirements of the digital twin system for crane main girders are effectively satisfied, laying a solid technical foundation for the lightweight development of crane digital twin models.