Prediction of load spectrum for crane life cycle and structural optimal design based on fatigue life

doi:10.3785/j.issn.1006-754X.2023.00.019

Chin J Eng Design

2023, Vol. 30

Issue (3): 380-389 DOI: 10.3785/j.issn.1006-754X.2023.00.019

Mechanical Strength Design

Prediction of load spectrum for crane life cycle and structural optimal design based on fatigue life

Qisong QI(

),Chenggang LI,Qing DONG,Yuhao CHEN,Hang XU

School of Mechanical Engineering, Taiyuan University of Science and Technology, Taiyuan 030024, China

Download:

HTML

PDF(1996KB)
Export: BibTeX | EndNote (RIS)

Abstract

Crane has been subjected to alternating loads with different characteristics for a long time during service, resulting in a decrease in load-bearing capacity due to structure fatigue. In order to study the impact of load and stress changes on the fatigue life of crane structure during actual work, firstly, a neural network was used to analyze the load spectrum of crane during service and accurately predict the load characteristics, and the stress-time history of the crane during service was analyzed by combining the accurately predicted load spectrum and structural bearing characteristics; secondly, Miner's linear damage accumulation theory and linear elastic fracture mechanics method were used to predict the fatigue life of the key parts of the crane structure; finally, with the fatigue life and structural bearing capacity of the key parts of the crane structure as constraints, an optimization design model considering the load characteristics of the crane during service was established. Intelligent optimization algorithm was used to search for the optimum design variable combination globally to obtain the optimum design parameters of the crane structure that met the design requirements of fatigue life and bearing capacity. The research results showed the feasibility of the method combining the calculation of structural fatigue life with intelligent optimization algorithm in the optimization design of crane structure, providing a new approach for the lightweight design of crane structure.

Key words： crane life cycle fatigue life optimal design

Received: 14 June 2022 Published: 06 July 2023

CLC:

TH 215

	Service
	E-mail this article
	Add to my bookshelf
	Add to citation manager
	E-mail Alert
	RSS
	Articles by authors
	Qisong QI
	Chenggang LI
	Qing DONG
	Yuhao CHEN
	Hang XU

Cite this article:

Qisong QI,Chenggang LI,Qing DONG,Yuhao CHEN,Hang XU. Prediction of load spectrum for crane life cycle and structural optimal design based on fatigue life. Chin J Eng Design, 2023, 30(3): 380-389.

URL:

https://www.zjujournals.com/gcsjxb/10.3785/j.issn.1006-754X.2023.00.019 OR https://www.zjujournals.com/gcsjxb/Y2023/V30/I3/380

起重机生命周期载荷谱预测及基于疲劳寿命的结构优化设计

起重机在服役期间长期承受具有不同特征的交变载荷的作用，其结构因疲劳而导致承载能力下降。为了研究在实际工作过程中载荷及应力变化对起重机结构疲劳寿命的影响，首先，利用神经网络对起重机在服役期间的载荷谱进行分析，准确预测其载荷特征，并结合预测的载荷谱及其结构承载特性分析起重机在服役期间的应力—时间历程；其次，利用Miner线性损伤累积理论和线弹性断裂力学法，预测起重机结构关键部位的疲劳寿命；最后，以起重机结构关键部位的疲劳寿命及结构承载能力为约束，建立考虑起重机服役期间载荷特征的优化设计模型，采用智能优化算法在全局范围内搜索最优设计变量组合，获取满足疲劳寿命和承载能力设计要求的起重机结构最佳设计参数。研究结果表明了结构疲劳寿命计算与智能优化算法相结合的方法在起重机结构优化设计中的可行性，为起重机结构的轻量化设计提供了全新的思路。

关键词： 起重机, 生命周期, 疲劳寿命, 优化设计

Fig.1 Schematic diagram of universal overhead crane

符号	参数	数值	单位
$S$	跨度	25.5	m
$Q$	起重量	20	t
$K$	大车基距	4 880	mm
$b$	小车轮距	2 360
$B$	小车轨道距离	2 700
$P m$	满载小车轮压	58.9	kN
$P k$	空载小车轮压	7.2	kN
$v q$	额定起升速度	8.2	m/min
$v d$	大车运行速度	60	m/min
$s d$	小车轮极限位置	480	mm

Table 1 Design parameters of crane

符号	参数	数值	单位
$X 1$	上翼缘板厚	16	mm
$X 2$	下翼缘板厚	16
$X 3$	主腹板厚	10
$X 4$	副腹板厚	8
$X 5$	腹板间距	500
$X 6$	腹板高度	1 300
$X 7$	上翼缘板宽	630
$X 8$	下翼缘板宽	610
$X 9$	翼缘板最大外伸	50
$X 10$	跨端腹板高度	500
$A z$	跨中截面面积	43 240	mm²
$A d$	跨端截面面积	29 840	mm²
$I z$	跨中截面惯性矩	1.19×10¹⁰	mm⁴
$I d$	跨端截面惯性矩	1.53×10⁹	mm⁴

Table 2 Cross-section parameters and their schemetics of crane main girder

工况	计算项	计算公式	单位
工况1	跨中弯矩	$M z_1 = 18 q S 2 + F m 2 S - b$	$N ? m m$
	跨中剪力	$F z_1 = - ? F m b S$	N
	跨端剪力	$F d_1 = q S 2 + F m 1 - ? b S$	N
	跨中扭矩	$T n_1 = 2 F m l o z$	$N ? m m$
工况2	跨中弯矩	$M z_2 = 18 q S 2 + 12 F m 2 s d + b$	$N ? m m$
	跨中剪力	$F z_2 = - ? F m 2 s d + b S$	N
	跨端剪力	$F d_2 = q S 2 + F m 2 - ? 2 s d + b S$	N
	跨端扭矩	$T n_2 = 2 F m l o d$	$N ? m m$
工况3	跨中弯矩	$M z_3 = 18 q S 2 + 12 F k 2 s d + b$	$N ? m m$
	跨中剪力	$F z_3 = - ? F k 2 s d + b S$	N
	跨端剪力	$F d_3 = q S 2 + F k 2 - ? 2 s d + b S$	N
	跨中扭矩	$T n_3 = 2 F k l o z$	$N ? m m$
工况4	跨中弯矩	$M z_4 = 18 q S 2 + F k s d + b 2$	$N ? m m$
	跨中剪力	$F z_4 = - ? F k 2 s d + b S$	N
	跨端剪力	$F d_4 = q S 2 + F k 2 s d + b S$	N
	跨端扭矩	$T n_4 = q S 2 + F k 2 s d + b S$	$N ? m m$

Table 3 Mechanical models and internal force calculation formulas of crane structure under different working conditions

截面	应力类别	符号	计算公式	最大应力工况		最小应力工况
截面	应力类别	符号	计算公式	计算点①	计算点②	计算点①
跨中截面	弯曲正应力	$σ s$	式(4)	69.40	68.37	18.38
	弯曲切应力	$τ z$	式(5)	2.05	2.09	-0.026
	扭转切应力	$τ n$	式(6)	3.16	3.41	0.27
	局部压应力	$σ m$	式(7)	0	57.51	0
	合成应力	$σ h z$	式(8)	80.32	64.28	18.39
跨端截面	弯曲切应力	$τ d$	式(5)	20.99		5.36
	扭转切应力	$τ n$	式(6)	5.79		0.52
	合成应力	$τ h d$	$τ h d = τ d + τ n$	26.78		5.88

Table 4 Stress calculation formulas and results of crane structure

优化项	参数	数值
优化项	参数	优化1	优化2	优化3	优化5	优化5	单位
设计变量	$X 1$	6	6	6	10	6	mm
	$X 2$	6	6	6	10	6
	$X 3$	6	6	6	6	6
	$X 4$	6	6	6	6	6
	$X 5$	520	520	520	450	540
	$X 6$	1 500	1 500	1 500	1 350	1 490
其他变量	$X 7$	644			574	664
	$X 8$	624			554	644
	$X 9$	50			50	50
	$X 10$	500			450	500
结构承载能力指标	跨中最大正应力	124.30			114.38	123.45	MPa
	跨端最大正应力	44.45			48.28	44.40	MPa
	跨中最大变形	25.37			25.41	25.34	mm
目标函数	f (X)	25 608			27 480	25 728	mm²

Table 5 Structural optimization results of crane main girder

Fig.2 Optimization iterative curves for crane main girder structure

编号 $i$	起升载荷 $Q i t / t$	循环数 $t i$ /次	编号 $i$	起升载荷 $Q i t / t$	循环数 $t i$ /次	编号 $i$	起升载荷 $Q i t / t$	循环数 $t i$ /次
1	19.2	92	10	15.2	81	19	10.2	53
2	17.4	85	11	15.0	52	20	10.0	43
3	17.0	98	12	14.8	86	21	8.8	42
4	16.8	68	13	12.8	57	22	8.6	57
5	16.6	77	14	12.6	50	23	8.4	31
6	16.4	57	15	12.2	53	24	7.6	42
7	15.8	63	16	11.6	71	25	6.8	50
8	15.6	92	17	11.4	64	26	6.6	35
9	15.4	63	18	10.6	58	27	6.4	43

Table 6 Characteristic parameters of crane load spectrum

Fig.3 Prediction model of crane load spectrum

Fig.4 Comparison of predicted and actual cycle times of crane

Fig.5 Stress-time history of crane structure (partial)

Fig.6 Optimization process of crane structure

Fig.7 Optimization iterative curves for cross-section area of the crane main girder span

Fig.8 Variation curves of fatigue life of crane structure

参数	数值							单位
参数	优化1	优化2	优化3	优化4	优化5	优化6	优化7	单位
$X 1$	16	8	8	10	12	12	14	mm
$X 2$	16	8	8	10	12	12	14
$X 3$	6	6	6	6	6	6	6
$X 4$	6	6	6	6	6	6	6
$X 5$	400	550	550	550	440	440	420
$X 6$	1 190	1 470	1 470	1 310	1 310	1 310	1 240
$A z$	30 728	28 264	28 264	29 000	29 016	29 016	29 832	mm²
$N f$	56.70	50.02	50.02	50.07	50.31	50.31	52.99	a
$σ m a x$	104.45	106.94	106.94	107.52	107.35	107.35	106.14	MPa
$f m a x ①$	25.45	21.73	21.73	24.28	24.21	24.21	25.06	mm

Table 7 Optimization results of crane structure based on fatigue life

Table 8 Comparison of crane structural performance indicators before and after optimization design


[1]	LIU Z C， GUO S S， WANG L. Integrated green scheduling optimization of flexible job shop and crane transportation considering comprehensive energy consumption［J］. Journal of Cleaner Production， 2019， 211： 765-786.

[2]	许文超，王登峰.基于疲劳寿命的驱动桥壳可靠性与轻量化设计［J］.中国公路学报，2020，33（5）：178-188. doi：10.3969/j.issn.1001-7372.2020.05.016 XU W C， WANG D F. Reliable and lightweight design for drive axle housing based on fatigue life［J］. China Journal of Highway and Transport， 2020， 33（5）： 182-192. doi: 10.3969/j.issn.1001-7372.2020.05.016

[3]	吕中意，王振玉，王庆莲，等.绿色物流背景下的模块化可扩容快递箱设计［J］.机械设计，2019，36（8）：48-54. LÜ Z Y， WANG Z Y， WANG Q L， et al. Design of the modular expansible packing box in the context of green logistics［J］. Journal of Machine Design， 2019， 36（8）： 48-54.

[4]	程贤福，周健，肖人彬，等.面向绿色制造的产品模块化设计研究综述［J］.中国机械工程，2020，31（21）：2612-2625. doi：10.3969/j.issn.1004-132X.2020.21.012 CHENG X F， ZHOU J， XIAO R B， et al. Review of product modular design from perspective of green manufacturing［J］. China Mechanical Engineering， 2020， 31（21）： 2612-2625. doi: 10.3969/j.issn.1004-132X.2020.21.012

[5]	杨瑞刚，刘玉珍，孟令军，等.起重机主梁结构可靠性混合模型的建立和分析［J］.安全与环境学报，2021，21（5）： 1897-1904. YANG R G， LIU Y Z， MENG L J， et al. Reliability analysis for the hybrid model of the crane structure［J］. Journal of Safety and Environment， 2021， 21（25）： 1897-1904.

[6]	李军，周伟，魏睿.基于混合GSA-GA的起重机主梁优化设计［J］.机械设计与制造，2021（10）：194-197. doi：10.3969/j.issn.1001-3997.2021.10.043 LI J， ZHOU W， WEI R. Optimization design of crane main beam based on hybrid GSA-GA［J］. Machinery Design & Manufacture， 2021（10）： 194-197. doi: 10.3969/j.issn.1001-3997.2021.10.043

[7]	焦洪宇，周奇才，吴青龙，等.桥式起重机箱型主梁周期性拓扑优化设计［J］.机械工程学报，2014， 50（23）： 134-139. doi：10.3901/jme.2014.23.134 JIAO H Y， ZHOU Q C， WU Q L， et al. Periodic topology optimization of the box-type girder of bridge crane［J］. Journal of Mechanical Engineering， 2014， 50（23）： 134-139. doi: 10.3901/jme.2014.23.134

[8]	SUN C L， TAN Y， ZENG J C， et al. The structure optimization of main beam for bridge crane based on an improved PSO［J］. Journal of Computers， 2011， 6（8）： 1585-1590.

[9]	渠晓刚，温鑫，张晓康.基于损伤力学的桥式起重机疲劳寿命分析［J］.安全与环境学报，2021，21（3）：1012-1016. QU X G， WEN X， ZHANG X K. Assessing and analysis of the fatigue life of the bridge-type crane based on the damage mechanics［J］. Journal of Safety and Environment， 2021， 21（3）： 1012-1016.

[10]	冯月贵，谢尧林，贾民平，等.基于顺序法的起重机疲劳寿命预测方法研究及应用［J］.起重运输机械，2013（2）：1-5. doi：10.3969/j.issn.1001-0785.2013.02.001 FENG Y G， XIE Y L， JIA M P， et al. Research and application of crane fatigue life prediction method based on sequential method［J］. Hoisting and Conveying Machinery， 2013（2）： 1-5. doi: 10.3969/j.issn.1001-0785.2013.02.001

[11]	范小宁，徐格宁，王爱红.基于人工神经网络获取起重机当量载荷谱的疲劳剩余寿命估算方法［J］.机械工程学报，2011，47（20）：69-74. doi：10.3901/jme.2011.20.069 FAN X N， XU G N， WANG A H. Evaluation method of remaining fatigue life for crane based on the acquisition of the equivalent load spectrum by the artificial neural network［J］. Journal of Mechanical Engineering， 2011， 47（20）： 69-74. doi: 10.3901/jme.2011.20.069

[12]	ÁVILA G， PALMA E， DE PAULA R. Crane girder fatigue life determination using SN and LEFM methods［J］. Engineering Failure Analysis， 2017， 79： 812-819.

[13]	DONG Q， XU G N， XIN Y S. Fatigue residual life prediction of casting crane under track defect model［J］. Journal of Advanced Mechanical Design， Systems， and Manufacturing， 2018， 12（4）： JAMDSM0092-JAMDSM 0092.

[14]	WANG J M， WANG R G， ZHU Y C， et al. Life cycle assessment and environmental cost accounting of coal-fired power generation in China［J］. Energy Policy， 2018， 115： 374-384.

[15]	徐建全，杨沿平.基于Vensim的汽车轻量化全生命周期动态评价［J］.计算机集成制造系统，2020，26（4）：954-969. XU J Q， YANG Y P. Dynamic evaluation of lightweight automobile life cycle based on Vensim software［J］. Computer Integrated Manufacturing Systems， 2020， 26（4）： 954-969.

[16]	张旭辉，郭欢欢，马宏伟，等.基于生命周期的采煤机绿色评价方法研究及应用［J］.煤炭科学技术，2021， 49（6）： 205-212. ZHANG X H， GUO H H， MA H W. Research and application of green evaluation method for shearer based on life cycle［J］. Coal Science and Technology， 2021， 49（6）： 205-212.

[17]	徐航，戚其松，董青，等.基于模糊数学的起重机结构绿色评价设计技术［J］.机械设计与研究，2021，37（1）： 200-204，214. XU H， QI Q S， DONG Q， et al. Study on green evaluation and design of crane structure based on fuzzy mathematics［J］. Machine Design & Research， 2021， 37（1）： 200-204， 214.

[18]	WEN B， JIN Q， HUANG H， et al. Life cycle assessment of quayside crane： A case study in China［J］. Journal of Cleaner Production， 2017， 148： 1-11.

[19]	顾复，顾新建，张武杰，等.透明公平的产品生命周期评价方法［J］.中国机械工程，2018，29（21）：2539-2545. doi：10.3969/j.issn.1004-132X.2018.21.004 GU F， GU X J， ZHANG W J， et al. Transparent and fair LCA method for products［J］. China Mechanical Engineering， 2018， 29（21）： 2539-2545. doi: 10.3969/j.issn.1004-132X.2018.21.004

[20]	万力，徐格宁，顾迪民，等. 起重机设计规范：［S］.北京：中国标准出版社，2008：9-30. WAN L， XU G N， GU D M， et al. Design rules for cranes：［S］. Beijing： China Standards Press， 2008： 9-30.

[1]	Yumin HE,Ying HAN,Jing ZHOU. Research on adaptive sliding mode control of tower crane based on improved fruit fly optimization algorithm[J]. Chin J Eng Design, 2023, 30(3): 271-280.

[2]	Chun-jian HUA,Dong-dong LI,Yi JIANG,Jian-feng YU,Ying CHEN. Study on fatigue life of shaft with V-notch under dual-frequency excitation[J]. Chin J Eng Design, 2023, 30(1): 102-108.

[3]	HAO Chun-yong, WANG Dong-liang, ZHENG Jin-yang, XU Ping, GU Chao-hua. Research on the relationship between burst pressure and fatigue life of composite hydrogen storage tank with aluminum liner[J]. Chin J Eng Design, 2021, 28(5): 594-601.

[4]	ZHANG Jin, LIU Pei-shan, YIN Yu-feng. Design and dynamic characteristics analysis of Y-shaped rotary ultrasonic motor[J]. Chin J Eng Design, 2021, 28(2): 248-254.

[5]	SUN Yue-hai, TANG Er-xing. Optimal design of basic parameters of spiral bevel gears[J]. Chin J Eng Design, 2020, 27(5): 616-624.

[6]	WANG Yu-pu, CHENG Wen-ming, DU Run, WANG Shu-biao, YANG Xing-zhou, ZHAI Shou-cai. Simulation analysis of wind load response for large gantry crane[J]. Chin J Eng Design, 2020, 27(2): 239-246.

[7]	CHEN Zhen, ZHOU Yang, JING Shuang, HUANG Zhi-qiang, CHEN Yan. Study on damage mechanism and fatigue life prediction of seismic vibrator baseplate[J]. Chin J Eng Design, 2019, 26(6): 658-665.

[8]	LI Song-mei, ZHENG Zhe, LI Shuai-shuai, CHANG De-gong. Structure and fatigue life analysis of damping type tripod universal joint[J]. Chin J Eng Design, 2019, 26(5): 520-526.

[9]	REN Zhong, XU Ge-ning, DONG Qing, LU Feng-yi, XU Tong. Lightweight design of main beam for bridge crane based on AFSA-GA serial algorithm[J]. Chin J Eng Design, 2019, 26(2): 197-205.

[10]	HUANG Zhi-qiang, XU Zi-yang, MU Xin-ming, LIANG Chun-ping, TANG Yu-jie. Design and analysis of semi-active crane heave compensation test rig[J]. Chin J Eng Design, 2019, 26(2): 215-222.

[11]	WANG Gang, HUANG Ling-hui, LIU Jin-jun. Research on dynamic stress and fatigue life for ultra-deep mine hoist drum[J]. Chin J Eng Design, 2018, 25(6): 703-710.

[12]	DENG Xing, YU Lan-feng, LEI Cong, XU Jiang-ping, XIAO Ze-ping. Lightweight design of trackless telescopic gantry crane based on response surface method[J]. Chin J Eng Design, 2018, 25(3): 288-294.

[13]	DENG Xing, YU Lan-feng, LEI Cong, XU Jiang-ping, XIAO Ze-ping. Research on contact problem of trackless telescopic gantry crane[J]. Chin J Eng Design, 2018, 25(1): 79-84,93.

[14]	CAI Yu-qiang, ZHU Dong-sheng. Analysis of crankshaft fatigue life of high-speed crank press based on dynamics simulation[J]. Chin J Eng Design, 2017, 24(6): 680-686.

[15]	LIU Wen, ZHANG Jin-hong, LIN Teng-jiao, YANG Yun, CAI Yun-long. Prediction and research on influencing factors of structural noise of bridge crane with three-point support[J]. Chin J Eng Design, 2017, 24(5): 580-587,594.

Viewed

Full text

Abstract

Cited

Shared

Discussed