The artificial potential field method is usually applied to the path planning problem of driverless cars or mobile robots. For example, it has been applied for the obstacle avoidance problem of intelligent cars and the autonomous navigation system of storage robots. However, there have been few studies on its application to intelligent bridge cranes. The artificial potential field method has the advantages of being a simple algorithm with short operation times. However, it is also prone to problems of unreachable targets and local minima. Based on the analysis of the operating characteristics of bridge cranes, a two-dimensional intelligent running environment model of a bridge crane was constructed in MATLAB. According to the basic theory of the artificial potential field method, the double-layer artificial potential field method was deduced, and the path and track fuzzy processing method was proposed. These two methods were implemented in MATLAB simulations. The results showed that the improved artificial potential field method could avoid static obstacles efficiently.

As the main bearing structure of the crane, the girder structure determines its service life. While the girder structure meets the strength, stiffness, and stability, its fatigue life should be paid more attention. A strong impact will be caused by the overhead travelling crane running through the uneven track joint. Based on SolidWorks and automated dynamic analysis of mechanical systems, the virtual prototype of 480 t overhead travelling crane operation is established in this study. The operation simulation of various track height differences is carried out. Compared with the theoretical calculation of GB and ISO, the virtual prototype is verified. Through the strain test and finite‐element calculation of stress of girder under the two working conditions including the main car with a load of 433 t running to the mid‐span and span end of the girder, the stress concentration in the transition rounded corner of the girder is found. On the basis of the simulation load spectrum and finite‐element static stress analysis, combined with the S–N curve of material, the fatigue damage and life prediction model of the 480 t overhead travelling crane girder is established. The minimum life of the dangerous part is obtained, providing a basis for the design and maintenance.

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