Control of an Underactuated Double-Pendulum Overhead Crane using Improved Model Reference Command Shaping: Design, Simulation and Experiment

This paper presents a new control scheme based on model reference command shaping (MRCS) for an overhead crane, with double-pendulum mechanism effects. The approach has an advantage in achieving an accurate trolley positioning, with low hook and payload oscillations, under various desired trolley positions and parameter uncertainties, without the requirement for measurement or estimation of system parameters. These are challenging in practice. The previously developed MRCS algorithm is improved in order to reduce its design complexity, as well as to ensure that it can be augmented with a feedback controller so that a concurrent controller tuning can be realised. The combined MRCS and feedback controller is used to achieve both, precise trolley positioning, and low hook and payload oscillations. To evaluate the effectiveness and the robustness of the approach, simulations and experiments using a nonlinear model and a laboratory double-pendulum crane are carried out. Under various desired positions and parameter uncertainties that involve varying the cable lengths (payload hoisting) and the payload mass variations, the superiority of the proposed approach is confirmed by achieving higher hook and payload oscillation reductions when compared with a recently proposed feedback controller. In addition, the desired trolley positions are achieved with smoother responses

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

Adaptive output-based command shaping for sway control of a 3D overhead crane with payload hoisting and wind disturbance

Payload hoisting and wind disturbance during crane operations are among the challenging factors that affect a payload sway and thus, affect the crane's performance. This paper proposes a new online adaptive output-based command shaping (AOCS) technique for an effective payload sway reduction of an overhead crane under the influence of those effects. This technique enhances the previously developed output-based command shaping (OCS) which was effective only for a fixed system and without external disturbances. Unlike the conventional input shaping design technique which requires the system's natural frequency and damping ratio, the proposed technique is designed by using the output signal and thus, an online adaptive algorithm can be formulated. To test the effectiveness of the AOCS, experiments are carried out using a laboratory overhead crane with a payload hoisting in the presence of wind, and with different payloads. The superiority of the method is confirmed by 82% and 29% reductions in the overall sway and the maximum transient sway respectively, when compared to the OCS, and two robust input shapers namely Zero Vibration Derivative-Derivative and Extra-Insensitive shapers. Furthermore, the method demonstrates a uniform crane's performance under all conditions. It is envisaged that the proposed method can be very useful in designing an effective controller for a crane system with an unknown payload and under the influence of external disturbances

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

Control of an underactuated double-pendulum overhead crane using improved model reference command shaping: Design, simulation and experiment

This paper presents a new control scheme based on model reference command shaping (MRCS) for an overhead crane, with double-pendulum mechanism effects. The approach has an advantage in achieving an accurate trolley positioning, with low hook and payload oscillations, under various desired trolley positions and parameter uncertainties, without the requirement for measurement or estimation of system parameters. These are challenging in practice. The previously developed MRCS algorithm is improved in order to reduce its design complexity, as well as to ensure that it can be augmented with a feedback controller so that a concurrent controller tuning can be realised. The combined MRCS and feedback controller is used to achieve both, precise trolley positioning, and low hook and payload oscillations. To evaluate the effectiveness and the robustness of the approach, simulations and experiments using a nonlinear model and a laboratory double-pendulum crane are carried out. Under various desired positions and parameter uncertainties that involve varying the cable lengths (payload hoisting) and the payload mass variations, the superiority of the proposed approach is confirmed by achieving higher hook and payload oscillation reductions when compared with a recently proposed feedback controller. In addition, the desired trolley positions are achieved with smoother responses

Modeling and control of 5-DoF boom crane

Automation of cranes can have a direct impact on the productivity of construction projects. In this paper, we focus on the control of one of the most used cranes, the boom crane. Tower cranes and overhead cranes have been widely studied in the literature, whereas the control of boom cranes has been investigated only by a few works. Typically, these works make use of simple models making use of a large number of simplifying assumptions (e.g. fixed length cable, assuming certain dynamics are uncoupled, etc.) A first result of this paper is to present a fairly complete nonlinear dynamic model of a boom crane taking into account all coupling dynamics and where the only simplifying assumption is that the cable is considered as rigid. The boom crane involves pitching and rotational movements, which generate complicated centrifugal forces, and consequently, equations of motion highly nonlinear. On the basis of this model, a control law has been developed able to perform position control of the crane while actively damping the oscillations of the load. The effectiveness of the approach has been tested in simulation with realistic physical parameters and tested in the presence of wind disturbances.Comment: the paper was published in 37th International Symposium on Automation and Robotics in Construction (ISARC 2020

Comparative Assessment of Feed-forward Schemes with NCTF for Sway and Trajectory Control of a DPTOC

This paper presents a comparative assessment of feed-forward schemes in hybrid control schemes for anti-swaying and trajectory tracking of a double-pendulum-type overhead crane (DPTOC) system. A nonlinear DPTOC system is considered and the dynamic model of the system is derived using the Euler-Lagrange formulation. To study the effectiveness of the controllers, initially nominal characteristics following trajectory following (NCTF) is developed for position control of cart movement. The controller design, which is comprised of a nominal characteristic trajectory (NCT) and PI compensator, is used to make the cart motion follow the NCT. This is then extended to incorporate feed-forward schemes for anti-swaying control of the system. Feed-forward control schemes based on input shaper and filtering techniques are to be examined. The input shaper and filtering techniques with different orders were designed based on properties of the system. The results of the response with the controllers are presented in time and frequency domains. The performances of hybrid control schemes are examined in terms of level of input tracking capability, sway angle reduction and time response specifications in comparison to NCTF controller. Finally, a comparative assessment of the control techniques is discussed and presented

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