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To address the problems of the lack of an online data simulation test environment, the poor openness of data collection, and the low degree of data visualization in the online control process of port cranes, an operation state monitoring system framework for port cranes based on digital twins is proposed. In this framework, the digital twin port crane is used as the core, and the multi-sensor data acquisition method, OPC UA information model, and plug-in programming method are combined to realize multi-source heterogeneous virtual and real data fusion. The digital twin crane monitoring system based on this framework can fulfil the following functions: crane historical operation process reproduction, control program simulation testing, synchronous mapping simulation, and remote control. In order to verify the proposed method, a digital twin-based physical platform for monitoring a rail-mounted gantry crane (RMGC) was built, in which a virtual test of anti-swing control and a digital twin monitoring experiment were carried out. The results show that the virtual RMGC can test the control algorithm and map the movement process of the physical RMGC, and the crane operation monitoring system has high real-time performance and good visualization effect. In addition, the remote control of the software platform is accurate and effective.

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