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ACKNOWLEDGEMENTS

There are many people who have helped me reach this point in my life, but none are more important than my parene teachers and professors who helped me along the way; my advisor, Dr. William Singhose, for his advice and guidance in preparing this thesis. Thanks be to my labmates, whose consistent help and input, made graduate school a great place to work.

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TABLE OF CONTENTS

ACKNOWLEDGEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . LIST OF TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

iii vii viii xii 1 1 4 10 11 11 14 17 19 21 23 27 27 31 33 34 35 38 41 44 44 47 48 51

LIST OF FIGURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SUMMARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 1.2 1.3 II Concepts: Boom Cranes . . . . . . . . . . . . . . . . . . . . . . . . . . . . Concepts: Input Shaping . . . . . . . . . . . . . . . . . . . . . . . . . . . Thesis Contributions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DYNAMIC BEHAVIOR OF BOOM CRANES . . . . . . . . . . . . . . . . . . 2.1 2.2 2.3 Mathematical Model - Mobile Boom Crane . . . . . . . . . . . . . . . . . Verication of Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lung Dynamics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3.1 2.3.2 2.3.3 2.4 Inertia Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kinematic Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pendulum Dynamics . . . . . . . . . . . . . . . . . . . . . . . . . .

Conventional Input Shaping . . . . . . . . . . . . . . . . . . . . . . . . . . 2.4.1 2.4.2 Lung Input Shaping . . . . . . . . . . . . . . . . . . . . . . . . . Lung Slewing Combination . . . . . . . . . . . . . . . . . . . . .

2.5

Vertically Accelerated Pendulums . . . . . . . . . . . . . . . . . . . . . . 2.5.1 2.5.2 2.5.3 2.5.4 Background . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Experimental Verication . . . . . . . . . . . . . . . . . . . . . . . Eects of Varying Step Time . . . . . . . . . . . . . . . . . . . . . Pulses in Acceleration . . . . . . . . . . . . . . . . . . . . . . . . .

III

CARTESIAN BOOM AND TOWER CRANE CONTROL STRATEGY . . . . 3.1 3.2 3.3 3.4 Cartesian Coordinate Transformation . . . . . . . . . . . . . . . . . . . . Actuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Saturation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Feedback Linearization . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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3.5 IV

Further Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

54 57 58 58 59 62 66 66 67 70 73 77 79 81 85 88 92 95 96 98 100 105 108 108 109 111 112 113 115 118

DESIGN OF A MOBILE BOOM CRANE . . . . . . . . . . . . . . . . . . . . 4.1 Design Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.1 4.1.2 4.2 Mechanical Design . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical/Control Design . . . . . . . . . . . . . . . . . . . . . . .

Additional Benets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INPUT-SHAPING FOR NON-LINEAR AND MULTI-MODE SYSTEMS . . . 5.1 Acceleration Limited Input Shaping . . . . . . . . . . . . . . . . . . . . . 5.1.1 5.1.2 5.1.3 5.1.4 5.2 Unaected Input Shapers . . . . . . . . . . . . . . . . . . . . . . . Predicting Shaper Degradation . . . . . . . . . . . . . . . . . . . . Improving Aected Input Shapers . . . . . . . . . . . . . . . . . . Concept Extensions . . . . . . . . . . . . . . . . . . . . . . . . . .

Nonlinear Braking Input Shaping . . . . . . . . . . . . . . . . . . . . . . . 5.2.1 5.2.2 5.2.3 5.2.4 ZV Shaping with a Braking Non-linearity . . . . . . . . . . . . . . UMZV Shaping with a Braking Nonlinearity . . . . . . . . . . . . Formulation and Implementation of a UMZVC Shaped Command Evaluation of UMZVC Commands . . . . . . . . . . . . . . . . . .

5.3

Minimum-Impulse Multi-Mode Input Shaper . . . . . . . . . . . . . . . . 5.3.1 5.3.2 5.3.3 5.3.4 Multi-Mode Input Shaping . . . . . . . . . . . . . . . . . . . . . . Design Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Two-Mode Example . . . . . . . . . . . . . . . . . . . . . . . . . . Experimental Results . . . . . . . . . . . . . . . . . . . . . . . . .

VI

APPLICATIONS ON AN INDUSTRIAL CRANE . . . . . . . . . . . . . . . . 6.1 System Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.1.1 6.2 Dynamic Model of Industrial Cranes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Integration of the Crane Control System 6.2.1 6.2.2 6.2.3 6.2.4

Human-Machine Interface . . . . . . . . . . . . . . . . . . . . . . . Feedback Control Components . . . . . . . . . . . . . . . . . . . . Anti-Sway & Positioning Control . . . . . . . . . . . . . . . . . . . Benecial Attributes of Combining Input Shaping with Feedback Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.3

Performance Evaluation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.3.1 6.3.2 6.3.3 Input Shaping Oscillation Suppression . . . . . . . . . . . . . . . . Disturbance Rejection . . . . . . . . . . . . . . . . . . . . . . . . . Positioning Capabilities . . . . . . . . . . . . . . . . . . . . . . . .

118 119 120 120 123 126 130 133

VII CONCLUSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . APPENDIX A APPENDIX B KANES METHOD SOURCE CODE . . . . . . . . . . . . . . . . LAGRANGES EQUATIONS SOURCE CODE . . . . . . . . . .

REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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LIST OF TABLES

2.1 2.2 2.3 2.4 5.1 5.2

Variables used in mobile boom crane model . . . . . . . . . . . . . . . . . . Comparison of Lung Frequency and Pendulum Frequency . . . . . . . . . Properties of Lung Experimental Apparatus . . . . . . . . . . . . . . . . . Physical Parameters Used in Experiment . . . . . . . . . . . . . . . . . . .

13 24 28 36 81 105

Bridge Crane Experimental Parameters. . . . . . . . . . . . . . . . . . . . . Summary of Input Shaper Duration and Insensitivity for 1 Hz and 4 Hz System. (Ordered by Duration) . . . . . . . . . . . . . . . . . . . . . . . . .

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LIST OF FIGURES

1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9

Two Types of boom cranes . . . . . . . . . . . . . . . . . . . . . . . . . . . Two Types of Mobile Boom Cranes (Size Scales Not Equal) . . . . . . . . . A Common Actuation System for a Boom Crane . . . . . . . . . . . . . . . Zero Vibration Response to Two Impulses . . . . . . . . . . . . . . . . . . . Input Shaping Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rise Time Increase Associated with Input Shaping . . . . . . . . . . . . . . Sensitivity Curves for ZV and ZVD Input Shapers . . . . . . . . . . . . . . Sensitivity Curve for SI Shaper. . . . . . . . . . . . . . . . . . . . . . . . . . Mobile Boom Crane Coordinate Diagram . . . . . . . . . . . . . . . . . . . Coordinate Frames Used to Dene Boom Crane Motion . . . . . . . . . . . Example Crane Maneuver Showing Congruence Between Mobile Boom Crane Model and a Stationary Boom Crane Model . . . . . . . . . . . . . . . . . . Example Base Maneuver Showing Congruence Between Mobile Boom Crane Model and Bridge Crane Model . . . . . . . . . . . . . . . . . . . . . . . . . Example Maneuver Showing Congruence Between Mobile Boom Crane Model Developed with Kanes Method and Lagranges Equations . . . . . . . . . . Block Diagram for Tower or Bridge Crane Motion . . . . . . . . . . . . . . Block Diagram for a Lung Motion on a Boom Crane . . . . . . . . . . . . Structural Diagram Showing Lung Cable Force . . . . . . . . . . . . . . . Free Body Diagram of Boom . . . . . . . . . . . . . . . . . . . . . . . . . .

1 2 3 5 5 6 7 8 12 12 15 16 17 17 18 19 20 22 25 26 27 29 30 31 31

2.10 Structural Diagram Showing Lung and Hoisting Cables . . . . . . . . . . 2.11 Comparison of Linear and Nonlinear Pendulum Responses for Constant Luing Motion and Payload Suspension Length . . . . . . . . . . . . . . . . . . 2.12 Contributions of Centripetal Acceleration and Cable Length Changes on Payload Natural Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13 Experimental Apparatus for Testing Lung Maneuvers . . . . . . . . . . . 2.14 Sensitivity Curves for Input Shapers Tested on Lung Maneuvers . . . . . 2.15 Amount of Residual Vibration for Lung Maneuvers of Varying Lung Durations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16 Velocity Prole of Proposed Lung Maneuver . . . . . . . . . . . . . . . . . 2.17 Velocity Prole of Proposed Lung Maneuver . . . . . . . . . . . . . . . . .

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2.18 Input Shaping Performance for Lung and Slewing Motions . . . . . . . . . 2.19 ZV and ZVD Performance for Lung and Slewing Motions . . . . . . . . . 2.20 Experimental Apparatus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21 Pendulum Frequency as a Function of Vertical Acceleration . . . . . . . . . 2.22 Variation in Response Amplitude and Phase Versus Step Switch Time . . . 2.23 Eect of a Pulse in Acceleration on Steady State Pendulum Response . . . 3.1 3.2 3.3 3.4 3.5 3.6 3.7 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 Spherical Coordinates of Boom Crane . . . . . . . . . . . . . . . . . . . . . Example Cartesian Motion and Velocity Proles . . . . . . . . . . . . . . . Transformation Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . Eect of Input Shaping on Cartesian Boom Motion. . . . . . . . . . . . . . Feedback Control Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . Cylindrical Coordinates of Tower Crane . . . . . . . . . . . . . . . . . . . . Articulated Boom lift and Coordinate System . . . . . . . . . . . . . . . . . Mobile Boom Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Four Bar Mechanism for Machine Vision Camera . . . . . . . . . . . . . . . Control Diagram for Mobile Boom Crane . . . . . . . . . . . . . . . . . . . Joypad Used for Manual Control of Mobile Boom Crane . . . . . . . . . . . Graphical User Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Webcams Used in Tele-Operation of Mobile Boom Crane . . . . . . . . . . . Extendible Boom Developed by Senior Design Students . . . . . . . . . . . Mobile Boom Crane Simulation . . . . . . . . . . . . . . . . . . . . . . . . . Electric Generator Trailer Used for Out-of-Laboratory Operation . . . . . . Eect of Acceleration Limiting . . . . . . . . . . . . . . . . . . . . . . . . . Nonlinear System is Reduced to a Linear System . . . . . . . . . . . . . . . Command Decomposition . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sensitivity curve for ZV Shaper . . . . . . . . . . . . . . . . . . . . . . . . . Amplitude of Residual Vibration as a Function of for Various Shapers . . Acceleration for a Three-Step Velocity Command . . . . . . . . . . . . . . . Sensitivity Curves for ZVD and ALZVD Input Shaper . . . . . . . . . . . . Sensitivity Curves for EI and ALEI Input Shaper . . . . . . . . . . . . . . . Sensitivity Curves for SI and ALSI Input Shaper . . . . . . . . . . . . . . .

32 33 35 37 40 41 45 50 52 53 54 54 55 58 60 60 61 61 62 63 64 64 66 68 69 70 73 73 75 76 76

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5.10 An Example of a Shaped and Unshaped Multi-Step Command . . . . . . . 5.11 Shaper Sensitivity to Damping Ratio . . . . . . . . . . . . . . . . . . . . . . 5.12 Non-Symmetrical Acceleration-Braking . . . . . . . . . . . . . . . . . . . . . 5.13 ZV and UMZV Shaped Pulse . . . . . . . . . . . . . . . . . . . . . . . . . . 5.14 Crane Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.15 Portable Crane Experimental Setup . . . . . . . . . . . . . . . . . . . . . . 5.16 Deconvolution of a ZV short command . . . . . . . . . . . . . . . . . . . . . 5.17 Deconvolution of a ZV long command . . . . . . . . . . . . . . . . . . . . . 5.18 ZV Interference Command . . . . . . . . . . . . . . . . . . . . . . . . . . .

77 78 79 80 80 81 82 82 83 84 84 85 86 86 87 88 91 94 94 95 96 97 102 103 104 104 104 105

5.19 Vibration Induced by ZV Shaped and Unshaped Pulse for Various Pulse Durations [b = 0.065 (s)] . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.20 Vibration Induced by ZV Shaped Pulse for Various Pulse Durations [same parameters as Figure 5.19] . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.21 Vibration of ZV Commands for Various tp and b . . . . . . . . . . . . . . . 5.22 Deconvolution of a UMZV Shaped Short Command . . . . . . . . . . . . .

5.23 UMZV Command Template . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.24 Vibration of Unshaped and UMZV Shaped Pulse for Various Pulse Durations [b = 0.065(s)] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.25 Vibration of UMZV Commands for Various tp and b . . . . . . . . . . . . . 5.26 Phasor Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.27 Constraints on a /T and b /T for a UMZVC Shaped Command . . . . . . . 5.28 UMZVC Shaped and Unshaped Vibration for Various Pulse Durations [b = 0.065(s)] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.29 Vibration of UMZVC Commands for Various tp and b . . . . . . . . . . . . 5.30 Convolution of two input shapers to form a two-mode shaper . . . . . . . . 5.31 Creating a two mode SI shaper . . . . . . . . . . . . . . . . . . . . . . . . . 5.32 Two-Mode Minimum-Impulse Input Shaper Solution . . . . . . . . . . . . . 5.33 Three possible input shapers for 1 =1Hz, 2 =4Hz . . . . . . . . . . . . . . 5.34 Sensitivity curve for 1 = 1Hz, 2 = 4Hz Short duration shaper . . . . . . . 5.35 Sensitivity curve for 1 = 1Hz, 2 = 4Hz Medium duration shaper . . . . . 5.36 Sensitivity curve for 1 = 1Hz, 2 = 4Hz Long duration shaper . . . . . . . 5.37 Diagram of Experimental Apparatus . . . . . . . . . . . . . . . . . . . . . .

5.38 Experimental response of short duration shaper . . . . . . . . . . . . . . . . 5.39 Experimental response of long duration shaper . . . . . . . . . . . . . . . . 6.1 6.2 6.3 6.4 Industrial Bridge Crane and its Controller Interface . . . . . . . . . . . . .

106 106 109 109 110

Crane Actuation Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . Expanded View of the Drives and Motors Block . . . . . . . . . . . . . . . . Comparison of the actual and modeled responses of the drives & motors to dierent velocity commands. (1) Response to a step of 100% velocity. (2) Response to a step of 50% velocity. (3) Response to a step from 100% velocity to -100% velocity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Components of the Crane Manipulation System. . . . . . . . . . . . . . . . Camera and LED Array Mounting Conguration. . . . . . . . . . . . . . . . Image captured and processed by the machine vision system (large photo). Close up photograph of the ducials mounted on the hook (sub photo). . . Banner LT7 Laser for Measuring the Position of the Bridge. . . . . . . . . . Anti-sway & Positioning Controller . . . . . . . . . . . . . . . . . . . . . . .

111 112 114 114 115 116 119 120 120 121 121 121

6.5 6.6 6.7 6.8 6.9

6.10 Motion-Induced Oscillation Suppression With and Without CMS Enabled . 6.11 Residual Hook Swing Amplitude After a Step Velocity Command was Issued to the Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.12 Residual Hook Swing Amplitude After a Pulse Velocity Command was Issued to the Crane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.13 Cancelation of Disturbance-Induced Oscillations . . . . . . . . . . . . . . .

6.14 Trolley Response to a Position Command of 1.25 m . . . . . . . . . . . . . . 6.15 Final Positioning Error Measured Radially from the Desired Position to the Actual Crane Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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SUMMARY

Millions of cranes are used around the world. Because of their wide-spread use in construction industries, boom cranes are an important class of cranes whose performance should be optimized. One limitation of most boom cranes is they are usually attached to a stationary base or a mobile base that is only used for initial positioning and not during operation. This limits the workspace of the boom crane signicantly. If a boom crane was attached to a mobile base that could be safely used during lifting operations, then the boom crane workspace could be extended signicantly. The problem with using cranes, and in particular mobile cranes, is the large oscillations of the payload that are typically induced when moving the crane. One control strategy that has been used to control oscillation on other types of cranes is called Input Shaping, a command ltering technique that reduces motion-induced vibration in oscillatory systems. This thesis develops a dynamics model for a mobile boom crane and analyzes the difculty of controlling payload oscillation on a boom crane. Input shaping will shown to be eective for controlling oscillation on boom cranes. A new method for operating a boom crane in Cartesian coordinates will also be shown. This thesis will also detail the design of a small-scale mobile boom crane for experimental and research purposes. A substantial part of this thesis will also focus on the development of new input-shaping methods for nonlinear drive systems commonly found on boom and other types of cranes. An example application of a control system featuring input shaping for an industrial bridge crane will also be discussed.

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