The crossbeam is frequently subjected to alternating loads during work as an essential load-bearing part of the crane. However, due to the large volume and the limitations of detection technology, it is impossible to realize online monitoring of the mechanical state. The ongoing advancement of ROMing and digital twin technology plays a pivotal role in facilitating the resolution of this particular issue. In this paper, we take the crane beam as the physical entity and combine the Twin Builder reduced-order technology and Deployer digital twin deployment technology to establish a digital twin of the beam. The load recognition model within the twin system exhibits a prediction error rate of ±5%. Furthermore, the accuracy of the ROM surpasses that of conventional machine learning models by a factor of 25. Upon deployment on the web platform, the results are delivered within 0.5 s, representing a substantial improvement as it is merely 1/15 of the time required for traditional 3D displays. The digital twin online monitoring system has the advantages of high accuracy and low requirements for monitoring equipment, which can be widely used in engineering practice to solve the problem that the mechanical state of large parts cannot be accurately monitored online.
Keywords: True-Load; Twin Builder; crane girder; online monitoring; reduced-order modelling.