Construction method and experimental validation of numerical simulation reduced-order model for gantry cranes

To address the low computational efficiency of full-order models (FOMs) for numerical simulations of gantry crane metal structures, taking the double-girder gantry crane as the research object, a quasi-static reduced-order model (ROM) suitable for outdoor dynamic environmental distrubances was built via Ansys Twin Builder. With identical computing resources, the simulation runtime is shortened from 100 s to the millisecond scale. And a metal structural health baseline comparison method for cranes based on this ROM was proposed. Experimental results showed that the ROM delivers high-fidelity stress predictions under both static and dynamic working conditions. The relative error between ROM simulation values and experimental measurements remains below 6.2% under dynamic environmental excitations, which validates the outstanding fidelity and real-time computing capacity of the proposed ROM. This study provides an effective engineering tool for evaluating the in-service state of crane metal structures.