Prediction of Remaining Fatigue Life of In-Service Bridge Cranes

Abstract

At present, bridge crane accidents occur frequently, resulting in significant losses and casualties; to ensure the safe use of in-service bridge cranes, it is necessary to predict the residual fatigue life of in-service bridge cranes. Firstly, a static analysis of the most dangerous working conditions of in-service bridge cranes is carried out to find the fatigue failure point. Subsequently, a three-parameter Weibull distribution model is established for the characteristic parameters affecting the acquisition of the stress spectrum. Latin hypercubic sampling is applied to randomly sample the characteristic parameters to produce a random sample set of characteristic parameters for use in obtaining the stress–time history. The amplitude and mean values of the stress spectra are obtained by cycle counting using the rainflow counting method. Finally, Forman’s formula and Miner’s continuous damage accumulation theory were used to derive the remaining life prediction equations for constant and variable amplitude loads. Comparing the remaining life obtained from the simulation and test, the error is about 9.145%, which proves that the remaining life obtained from the simulation is more accurate. The results show that the combined method of simulation and testing is feasible and can predict the remaining life more accurately. In the past, the prediction of residual life was performed with either testing or simulation, which is long and costly. Simulation is low-cost and takes a short time, but the accuracy is not high. In this paper, the combination method of testing and simulation improves the efficiency of production and reduces the cost of use.