Advanced Discrete-Time Control Methods for Industrial Applications

This thesis focuses on developing advanced control methods for two industrial systems in discrete-time aiming to enhance their performance in delivering the control objectives as well as considering the practical aspects. The first part addresses wind power dispatch into the electricity network using a battery energy storage system (BESS). To manage the amount of energy sold to the electricity market, a novel control scheme is developed based on discrete-time model predictive control (MPC) to ensure the optimal operation of the BESS in the presence of practical constraints. The control scheme follows a decision policy to sell more energy at peak demand times and store it at off-peaks in compliance with the Australian National Electricity Market rules. The performance of the control system is assessed under different scenarios using actual wind farm and electricity price data in simulation environment. The second part considers the control of overhead crane systems for automatic operation. To achieve high-speed load transportation with high-precision and minimum load swings, a new modeling approach is developed based on independent joint control strategy which considers actuators as the main plant. The nonlinearities of overhead crane dynamics are treated as disturbances acting on each actuator. The resulting model enables us to estimate the unknown parameters of the system including coulomb friction constants. A novel load swing control is also designed based on passivity-based control to suppress load swings. Two discrete-time controllers are then developed based on MPC and state feedback control to track reference trajectories along with a feedforward control to compensate for disturbances using computed torque control and a novel disturbance observer. The practical results on an experimental overhead crane setup demonstrate the high performance of the designed control systems.Comment: PhD Thesis, 230 page

Fuzzy sliding mode control of an offshore container crane

© 2017 A fuzzy sliding mode control strategy for offshore container cranes is investigated in this study. The offshore operations of loading and unloading containers are performed between a mega container ship, called the mother ship, and a smaller ship, called the mobile harbor (MH), which is equipped with a container crane. The MH is used to transfer the containers, in the open sea, and deliver them to a conventional stevedoring port, thereby minimizing the port congestion and also eliminating the need of expanding outwards. The control objective during the loading and unloading process is to keep the payload in a desired tolerance in harsh conditions of the MH motion. The proposed control strategy combines a fuzzy sliding mode control law and a prediction algorithm based on Kalman filtering for the MH roll angle. Here, the sliding surface is designed to incorporate the desired trolley trajectory while suppressing the sway motion of the payload. To improve the control performance, the discontinuous gain of the sliding control is adjusted with fuzzy logic tuning schemes with respect to the sliding function and its rate of change. Chattering is further reduced by a saturation function. Simulation and experimental results are provided to verify the effectiveness of the proposed control system for offshore container cranes

Model predictive control for improving operational efficiency of overhead cranes

Model predictive control (MPC) has been successfully applied to many transportation systems. For the control of overhead cranes, existing MPC approaches mainly focus on improving the regulation performance, such as tracking error or steady-state error. In this paper, energy efficiency as well as safety is newly considered in our proposed MPC approach. Based on the system model designed, the MPC approach is applied to minimize an objective function that is formulated as the integration of energy consumption and swing angle. In our approach, promising results in terms of low energy consumption and small swing angle can be found, whilst the solutions obtained can satisfy all practical constraints. Our test results indicate that the MPC approach can ensure stability and robustness of improving energy efficiency and safety.http://link.springer.com/journal/110712016-03-31hb201

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

Controller design for gantry crane system using modified sine cosine optimization algorithm

The objective of this research paper is to design a control system to optimize the operating works of the gantry crane system. The dynamic model of the gantry crane system is derived in terms of trolley position and payload oscillation, which is highly nonlinear. The crane system should have the capability to transfer the material to destination end with desired speed along with reducing the load oscillation, obtain expected trolley position and preserving the safety. Proposed controlling method is based on the proportional-integral-derivative (PID) controller with a series differential compensator to control the swinging of the payload and the system trolley movement in order to perform the optimum utilization of the gantry crane.  Standard sine cosine optimization algorithm is one of the most-recent optimization techniques based on a stochastic algorithm was presented to tune the PID controller with a series differential compensator. Furthermore, the considered optimization algorithm is modified in order to overcome the inherent drawbacks and solve complex benchmark test functions and to find the optimal design's parameters of the proposed controller. The simulation results show that the modified sine cosine optimization algorithm has better global search performance and exhibits good computational robustness based on test functions. Moreover, the results of testing the gantry crane model reveal that the proposed controller with standard and modified algorithms is effective, feasible and robust in achieving the desired requirements

Minimum Time Control of a Gantry Crane System with Rate Constraints

This paper focuses on the development of minimum time control profiles for point-to-point motion of a gantry crane system in the presence of uncertainties in modal parameters. Assuming that the velocity of the trolley of the crane can be commanded and is subject to limits, an optimal control problem is posed to determine the bang-off-bang control profile to transition the system from a point of rest to the terminal states with no residual vibrations. Both undamped and underdamped systems are considered and the variation of the structure of the optimal control profiles as a function of the final displacement is studied. As the magnitude of the rigid body displacement is increased, the collapse and birthing of switches in the optimal control profile are observed and explained. Robustness to uncertainties in modal parameters is accounted for by forcing the state sensitivities at the terminal time to zero. The observation that the time-optimal control profile merges with the robust time-optimal control is noted for specific terminal displacements and the migration of zeros of the time-delay filter parameterizing the optimal control profile are used to explain this counter intuitive result. A two degree of freedom gantry crane system is used to experimentally validate the observations of the numerical studies and the tradeoff of increase in maneuver time to the reduction of residual vibrations is experimentally illustrated

Input shaping-based control schemes for a three dimensional gantry crane

The motion induced sway of oscillatory systems such as gantry cranes may decrease the efficiency of production lines. In this thesis, modelling and development of input shaping-based control schemes for a three dimensional (3D) lab-scaled gantry crane are proposed. Several input shaping schemes are investigated in open and closed-loop systems. The controller performances are investigated in terms of trolley position and sway responses of the 3D crane. Firstly, a new distributed Delay Zero Vibration (DZV) shaper is implemented and compared with Zero Vibration (ZV) shaper and Zero Vibration Derivative (ZVD) shaper. Simulation and experimental results show that all the shapers are able to reduce payload sway significantly while maintaining desired position response specifications. Robustness tests with ±20% error in natural frequency show that DZV shaper exhibits asymmetric robustness behaviour as compared to ZV and ZVD shapers. Secondly, as analytical technique could only provide good performance for linear systems, meta-heuristic based input shaper is proposed to reduce sway of a gantry crane which is a nonlinear system. The results show that designing meta-heuristic-based input shapers provides 30% to 50% improvement as compared to the analytical-based shapers. Subsequently, a particle swarm optimization based optimal performance control scheme is developed in closed-loop system. Simulation and experimental results demonstrate that the controller gives zero overshoot with 60% and 20% improvements in settling time and integrated absolute error value of position response respectively, as compared to a specific designed PID-PID anti swing controller for the lab-scaled gantry crane. It is found that crane control with changing cable length is still a problem to be solved. An adaptive input shaping control scheme that can adapt to variation of cable’s length is developed. Simulation with real crane dimensions and experimental results verify that the controller provides 50% reduction in payload sway for different operational commands with hoisting as compared to the average travel length approach

Robust Control of Crane with Perturbations

In the presence of persistent perturbations in both unactuated and actuated dynamics of crane systems, an observer-based robust control method is proposed, which achieves the objective of trolley positioning and cargo swing suppression. By dealing with the unactuated and unknown perturbation as an augmented state variable, the system dynamics are transformed into a quasi-chain-of-integrators form based on which a reduced-order augmented-state observer is established to recover the perturbations appearing in the unactuated dynamics. A novel sliding manifold is constructed to improve the robust performance of the control system, and a linear control law is presented to make the state variables stay on the manifold in the presence of perturbations in unactuated dynamics. A Lyapunov function candidate is constructed, and the entire closed-loop system is proved rigorously to be exponentially stable at the equilibrium point. The effectiveness and robustness of the proposed observer-based robust controller are verified by numerical simulation results