Development of Motion Control Systems for Hydraulically Actuated Cranes with Hanging Loads

Automation has been used in industrial processes for several decades to increase efficiency and safety. Tasks that are either dull, dangerous, or dirty can often be performed by machines in a reliable manner. This may provide a reduced risk to human life, and will typically give a lower economic cost. Industrial robots are a prime example of this, and have seen extensive use in the automotive industry and manufacturing plants. While these machines have been employed in a wide variety of industries, heavy duty lifting and handling equipment such as hydraulic cranes have typically been manually operated. This provides an opportunity to investigate and develop control systems to push lifting equipment towards the same level of automation found in the aforementioned industries. The use of winches and hanging loads on cranes give a set of challenges not typically found on robots, which requires careful consideration of both the safety aspect and precision of the pendulum-like motion. Another difference from industrial robots is the type of actuation systems used. While robots use electric motors, the cranes discussed in this thesis use hydraulic cylinders. As such, the dynamics of the machines and the control system designmay differ significantly. In addition, hydraulic cranes may experience significant deflection when lifting heavy loads, arising from both structural flexibility and the compressibility of the hydraulic fluid. The work presented in this thesis focuses on motion control of hydraulically actuated cranes. Motion control is an important topic when developing automation systems, as moving from one position to another is a common requirement for automated lifting operations. A novel path controller operating in actuator space is developed, which takes advantage of the load-independent flow control valves typically found on hydraulically actuated cranes. By operating in actuator space the motion of each cylinder is inherently minimized. To counteract the pendulum-like motion of the hanging payload, a novel anti-swing controller is developed and experimentally verified. The anti-swing controller is able to suppress the motion from the hanging load to increase safety and precision. To tackle the challenges associated with the flexibility of the crane, a deflection compensator is developed and experimentally verified. The deflection compensator is able to counteract both the static deflection due to gravity and dynamic de ection due to motion. Further, the topic of adaptive feedforward control of pressure compensated cylinders has been investigated. A novel adaptive differential controller has been developed and experimentally verified, which adapts to system uncertainties in both directions of motion. Finally, the use of electro-hydrostatic actuators for motion control of cranes has been investigated using numerical time domain simulations. A novel concept is proposed and investigated using simulations.publishedVersio

Development of 3D anti-Swing control for hydraulic knuckle boom crane

In this paper, 3D anti-swing control for a hydraulic loader crane is presented. The difference between hydraulic and electric cranes are discussed to show the challenges associated with hydraulic actuation. The hanging load dynamics and relevant kinematics of the crane are derived to model the system and create the 3D anti-swing controller. The anti-swing controller generates a set of tool point velocities which are added to the electro-hydraulic motion controller via feedforward. A dynamic simulation model of the crane is made, and the control system is evaluated in simulations with a path controller in actuator space. Simulation results show significant reduction in the load swing angles during motion using the proposed anti-swing controller in addition to pressure feedback. Experiments are carried out to verify the performance of the anti-swing controller. Results show that the implemented pressure feedback is crucial for reaching stability, and with it the control system yields good suppression of the swing angles in practice.publishedVersio

Simulation of control drives in a tower crane

The design of a control system for a tower crane is investigated. Underlying the controller design is the theory of optimal linear control. Computer models of a crane and the control systems for the crane drives are developed. Simulation data reveals that the motion of the load can be effectively controlled so that it should follow a predetermined trajectory

Multi-objective Anti-swing Trajectory Planning of Double-pendulum Tower Crane Operations using Opposition-based Evolutionary Algorithm

Underactuated tower crane lifting requires time-energy optimal trajectories for the trolley/slew operations and reduction of the unactuated swings resulting from the trolley/jib motion. In scenarios involving non-negligible hook mass or long rig-cable, the hook-payload unit exhibits double-pendulum behaviour, making the problem highly challenging. This article introduces an offline multi-objective anti-swing trajectory planning module for a Computer-Aided Lift Planning (CALP) system of autonomous double-pendulum tower cranes, addressing all the transient state constraints. A set of auxiliary outputs are selected by methodically analyzing the payload swing dynamics and are used to prove the differential flatness property of the crane operations. The flat outputs are parameterized via suitable B\'{e}zier curves to formulate the multi-objective trajectory optimization problems in the flat output space. A novel multi-objective evolutionary algorithm called Collective Oppositional Generalized Differential Evolution 3 (CO-GDE3) is employed as the optimizer. To obtain faster convergence and better consistency in getting a wide range of good solutions, a new population initialization strategy is integrated into the conventional GDE3. The computationally efficient initialization method incorporates various concepts of computational opposition. Statistical comparisons based on trolley and slew operations verify the superiority of convergence and reliability of CO-GDE3 over the standard GDE3. Trolley and slew operations of a collision-free lifting path computed via the path planner of the CALP system are selected for a simulation study. The simulated trajectories demonstrate that the proposed planner can produce time-energy optimal solutions, keeping all the state variables within their respective limits and restricting the hook and payload swings.Comment: 14 pages, 14 figures, 6 table

Modelling and Control of a Knuckle Boom Crane

Cranes come in various sizes and designs to perform different tasks. Depending on their dynamic properties, they can be classified as gantry cranes and rotary cranes. In this paper we will focus on the so called 'knuckle boom' cranes which are among the most common types of rotary cranes. Compared with the other kinds of cranes (e.g. boom cranes, tower cranes, overhead cranes, etc), the study of knuckle cranes is still at an early stage and very few control strategies for this kind of crane have been proposed in the literature. Although fairly simple mechanically, from the control viewpoint the knuckle cranes present several challenges. A first result of this paper is to present for the first time a complete mathematical model for this kind of crane where it is possible to control the three rotations of the crane (known as luff, slew, and jib movement), and the cable length. The only simplifying assumption of the model is that the cable is considered rigid. On the basis of this model, we propose a nonlinear control law based on energy considerations which is able to perform position control of the crane while actively damping the oscillations of the load. The corresponding stability and convergence analysis is carefully proved using the LaSalle's invariance principle. The effectiveness of the proposed control approach has been tested in simulation with realistic physical parameters and in the presence of model mismatch.Comment: This paper has been accepted to International Journal of Control on March 29th 2021. arXiv admin note: text overlap with arXiv:2103.0250

Suspended Load Path Tracking Control Using a Tilt-rotor UAV Based on Zonotopic State Estimation

This work addresses the problem of path tracking control of a suspended load using a tilt-rotor UAV. The main challenge in controlling this kind of system arises from the dynamic behavior imposed by the load, which is usually coupled to the UAV by means of a rope, adding unactuated degrees of freedom to the whole system. Furthermore, to perform the load transportation it is often needed the knowledge of the load position to accomplish the task. Since available sensors are commonly embedded in the mobile platform, information on the load position may not be directly available. To solve this problem in this work, initially, the kinematics of the multi-body mechanical system are formulated from the load's perspective, from which a detailed dynamic model is derived using the Euler-Lagrange approach, yielding a highly coupled, nonlinear state-space representation of the system, affine in the inputs, with the load's position and orientation directly represented by state variables. A zonotopic state estimator is proposed to solve the problem of estimating the load position and orientation, which is formulated based on sensors located at the aircraft, with different sampling times, and unknown-but-bounded measurement noise. To solve the path tracking problem, a discrete-time mixed $\mathcal{H}_2/\mathcal{H}_\infty$ controller with pole-placement constraints is designed with guaranteed time-response properties and robust to unmodeled dynamics, parametric uncertainties, and external disturbances. Results from numerical experiments, performed in a platform based on the Gazebo simulator and on a Computer Aided Design (CAD) model of the system, are presented to corroborate the performance of the zonotopic state estimator along with the designed controller

A Hybrid Control Approach for the Swing Free Transportation of a Double Pendulum with a Quadrotor

In this article, a control strategy approach is proposed for a system consisting of a quadrotor transporting a double pendulum. In our case, we attempt to achieve a swing free transportation of the pendulum, while the quadrotor closely follows a specific trajectory. This dynamic system is highly nonlinear, therefore, the fulfillment of this complex task represents a demanding challenge. Moreover, achieving dampening of the double pendulum oscillations while following a precise trajectory are conflicting goals. We apply a proportional derivative (PD) and a model predictive control (MPC) controllers for this task. Transportation of a multiple pendulum with an aerial robot is a step forward in the state of art towards the study of the transportation of loads with complex dynamics. We provide the modeling of the quadrotor and the double pendulum. For MPC we define the cost function that has to be minimized to achieve optimal control. We report encouraging positive results on a simulated environmentcomparing the performance of our MPC-PD control circuit against a PD-PD configuration, achieving a three fold reduction of the double pendulum maximum swinging angle.This work has been partially supported by FEDER funds through MINECO project TIN2017-85827-P, and project KK-202000044 of the Elkartek 2020 funding program of the Basque Government. This project has received funding from the European Union’s Horizon 2020 research and innovation programme under the Marie Sklodowska-Curie grant agreement No 777720

Implicit IDA-PBC Design and Implementation for a Portal Crane System

Interconnection and damping assignment passivity-based control (IDA-PBC) is a wellknown technique which regulates the behavior of nonlinear systems, assigning a target port-Hamiltonian (pH) structure to the closed-loop. In underactuated mechanical systems (UMSs) its application requires the satisfaction of matching conditions, which in many cases demands to solve partial differential equations (PDEs). Only recently, the IDA-PBC has been extended to UMSs modeled implicitly, where the system dynamics in pH representation are described by a set of differential-algebraic equations (DAEs). In some system classes this implicit approach allows to circumvent the PDE problem and also to design an output-feedback law. The present thesis deals with the design and implementation of the total energy shaping implicit IDA-PBC on a portal crane system located at the laboratory of the Control Engineering Group at TU-Ilmenau. The implicit controller is additionally compared with a simplified (explicit) IDA-PBC [1]. This algorithm shapes the total energy and avoids the PDE problem. However, this thesis reveales a significant implementation flaw in the algorithm, which then could be solved.Interconnection and damping assignment passivity-based control (IDA-PBC) ist eine wohlbekannte Methode zur Regelung von nichtlinearen Systemen, die im geschlossenen Regelkreis eine gewünschte Port-Hamiltonian-Struktur (pH) haben. Die Anwendung auf unteraktuierte mechanische Systeme (UMS) erfordert die Erfüllung von sogenannten Matching Conditions, die meistens die Lösung partieller Differentialgleichungen (PDE) benötigt. Erst kürzlich wurde die IDA-PBC auf implizit modellierte UMS erweitert, bei denen die Systemdynamik in pH-Darstellungen durch Differentialalgebraische Gleichungen (DAE) beschrieben wird. Dieser implizite Ansatz ermöglicht bei einigen Systemklassen, das PDE-Problem zu umgehen und auch eine Ausgangsrückführung zu entwerfen. Die vorliegende Masterarbeit beschäftigt sich mit dem Entwurf und der Implementierung des impliziten IDA-PBC zur Gesamtenergievorgabe auf einem Portalkransystem im Labor des Fachgebiets Regelungstechnik der TU-Ilmenau. Der implizite Regler wird mit einem vereinfachten (expliziten) IDA-PBC verglichen [1]. Dieser Algorithmus gibt ebenso die Gesamtenergie vor und vermeidet das PDE-Problem. In der Masterarbeit wird in diesem Algorithmus ein wesentlicher Implementierungsfehler offengelegt und behoben.Tesi