A Method for Constructing a Digital Twin Monitoring System for Bridge Cranes Based on Unity3D

Abstract

With the rapid advancement of intelligent manufacturing, ensuring the safe operation and real-time monitoring of bridge cranes has become increasingly critical. Traditional monitoring methods are often hampered by data silos, limited real-time capabilities, and weak visualization, failing to meet the demands of modern industrial equipment management. To address these challenges, this study developed a digital twin-based monitoring system for bridge cranes using the Unity3D engine. The system integrates 3D modeling, physical simulation, and cyber-physical data interaction to enable real-time visualization and historical reconstruction of operational status. A multi-layer architecture—comprising data acquisition, processing, virtual model construction, and application display—was designed to integrate multi-source sensor data and support real-time mapping of key components such as the trolley, bridge travel mechanism, and hoisting device. The system was validated experimentally using a 20-ton double-girder bridge crane in an industrial indoor environment, demonstrating high-precision synchronization with the physical entity, along with reliable monitoring, historical replay, and anomaly recognition. This approach provides practical value for industry users by enhancing operational safety, facilitating predictive maintenance, and improving intelligent management of special industrial equipment.