柔性电缆疲劳寿命预测方法研究概述
Review of Research Methods for Fatigue Life Prediction of Flexible Cables
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摘要: 柔性电缆在运行过程中受到循环弯曲、拉伸与扭转等动态载荷的影响,其内部导体与绝缘层易出现累积损伤而导致疲劳失效,使用寿命大幅降低,对设备的稳定运行和人员安全造成巨大影响。通过对柔性电缆疲劳寿命预测,可以提前发现故障点,保障机器人等自动化设备正常运行,降低经济损失。本研究在理解柔性电缆的疲劳失效机理的基础上,系统梳理了柔性电缆疲劳寿命预测方法,基于有限元仿真构建模型与寿命模型分析的预测方法,存在对模型依赖性高、对复杂工况适应性不足等问题;以神经网络为代表的人工智能方法,在处理柔性电缆的非线性复杂工况和预测精度等方面表现出巨大优势,但存在难以实时关联实际工况的局限。融合数字孪生框架与智能算法的疲劳寿命预测方法,通过实时数据采集与模型动态校准,能够实现对柔性电缆动态寿命的全周期预测,将成为该领域未来发展的主流趋势。Abstract: Flexible cables, widely used in dynamic scenarios such as industrial automation and marine engineering, are susceptible to fatigue failure due to cyclic bending, stretching, and twisting, leading to cumulative damage in internal conductors and insulation layers, reduced service life, and threats to equipment stability and personnel safety. By predicting the fatigue life of flexible cables, potential failures can be identified early, the normal operation of automated equipment can be ensured, and economic losses can be reduced. Fatigue life prediction methods for flexible cables are systematically summarized in this review. Methods based on finite element simulation (model construction and life model analysis) are subject to high model dependency and insufficient adaptability to complex operating conditions. Significant advantages in handling nonlinear complex operating conditions and improving prediction accuracy are shown by artificial intelligence methods, represented by neural networks, but challenges in correlating with real-time operating conditions are faced by them. The integration of digital twin frameworks and intelligent algorithms, enabling full-cycle prediction of dynamic life through real-time data acquisition and dynamic model calibration, is expected to be the mainstream trend in this field.
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