Increasing the Reliability of Industrial Overhead Cranes by Structural Health Monitoring

Abstract

Overhead cranes are subjected to significant cyclic loads and stresses during their operation, which can lead to fatigue cracking and other forms of damage. Their correct and safe operation is critical while lifting and handling loads. Therefore, industrial cranes are subjected to periodic inspections and maintenance. However, inspections only give information on the condition of a crane at a certain moment and focus on propagating damage, which typically occur near the end of the life of the structure. This paper presents a Structural Health Monitoring (SHM) system that uses strain sensors combined with operational crane data (trolley position and hook load) to continuously monitor the crane structural response. A numerical model analyses the data stream to determine the fatigue life consumption and detect anomalies. This model is based on a digital twin of the overhead crane. The output of the SHM system assists maintenance personnel in identifying and addressing potential problems at critical areas before they result in costly failures or accidents. In addition, SHM can help extend the service life of overhead cranes, reducing the need for expensive replacements and helping to ensure the continued safety and efficiency of industrial operations. This paper, presents a pilot project implementing an SHM system on a small capacity crane (12.5 ton).