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CONTROL STRATE Gffi S FOR AUTOMAT][C GANTRY CRANE SYSTEM

BY

JAMAL UD][N JALANl

][NTERNAT][ONAL ][SLAM][C 1UNWJERS][TY MALAYS][A

J1UNE 2005

CONTROL STRATEGIES FOR AUTOMATIC GANTRY CRANE SYSTEM

BY

JAMAlL lUIDIN JAJLANI

A DISSERTATION SlUBMITTED IN PARTIAL FlULFILMENT OF TlHlJE REQ1[J]IJR]EMENTS

FOR TlHlJE DEGREE OF MASTER OF SCRENCE liN MEC1ffiA TRONIC§

ENGliNEERJING

KlULLliYYAH OF ENGliNEERJING INTERNATIONAL ISLAMIC lUNlMERSITY

MAlLAYSliA

ruNE 2005

ABSTRACT

Gantry crane is a machine that moves payload from one point to another point.

Nowadays, most of gantry cranes use open loop system to control position while anti

swing control is operated manually by skillful operators. The open loop system is

sensitive to the parameter variations and disturbances while operator's skills are

restricted by fatigue problem and will affect the performance of the gantry crane. In

order to overcome the problems, feedback control is adopted in this study. Firstly,

classical PID and PD were introduced as position and anti-swing control respectively.

The experimental result showed that the PID and PD controllers were successfully

controlled both position and swing of the gantry crane especially for small load

displacement. However, the positioning performance was degraded due to the

saturation of the actuator. In addition, the PID controller design is a time consuming

process, since model and parameters of the gantry crane are needed. Secondly, non

model based of fuzzy logic controllers are implemented in the gantry crane system for

position and anti-swing control. The experimental result showed that fuzzy logic

controllers had resulted on good performances for anti-swing controller. However, the

results for position control were inconsistent for small desired position. The tuning

process may improve the control performance but it may affect other desired

positions. Finally, non-model based of NCTF controller, was proposed for position

control of the gantry crane system while the anti-swing control by using fuzzy logic

controller remained the same since it gave good performance. The experimental result

showed that the NCTF controller produced best results for position control of the

gantry crane system compared to other controllers.

11

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l) ~I ~ (" ..w ,j5'WI o.u, ~ ~I J>--i if).c!)I JJI ~bi l) )~

4....LQj ~ ~..\.).A:JI PID ,PD t},j.-.i 01 '~i~IJ...u1 o.u, l) oJ.j)1 ~..wl

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JJI Lhi·~ I.~ '-" - .)·i I" J...::......j ~ - II;;..;, ·\1 ;;".....LA]I ~I)I ~i 01 ,l..i~ i '-:?~{~.r~ I..? y--" - -. <-

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~bi ~ 0i ~I if ~.rII~) .~~)I 0~1 c!l}1 c:: wlp ~ c!}1

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~i ~b..:....o~ NCTF ~I)I ~i 0i ~.rdl ~I ~)i) .\~

.~I)I ~i ~ c:: :ijJW~ c!)1 JJI itt.; c!r oJb)'

iii

APPROVAL PAGE

I certify that I have supervised and read this study and that in my opinion, it conforms to acceptable standards of scholarly presentation and is fully adequate, in scope and quality, as a thesis for the degree of Master of Science in Mechatronics Engineering.

w~c2···························· su~i~sor I certify that I have read this study and that in my opinion, it conforms to acceptable standards of scholarly presentation and is fully adequate, in scope and quality, as a thesis for the degree of Master of Science in Mechatronics Engineering.

~ ...... ~ ............................. . Abdulgani Albagul Internal Examiner

I certify that I have read this study and that, in my opinion, it conforms to acceptable standards of scholarly presentation and is fully adequate, in scope and quality, as a thesis for the degree of Master of Science in Mechatronics Engineering.

The thesis was submitted to the Department of Mechatronics Engineering and is accepted as pmiial fulfilment of the requirements for the degree of Master of Science in Mechatronics Engineering. $7-

....... /~~~" ................ . Mir Nasiri Nazim Head, Depmiment of Mechatronics Engineering

The thesis was submitted to the Kulliyah of Engineering and is accepted as partial fulfilment of the requirements for the degree of Master of Science in Mechatroni s Engineering. ~

lmad Faris Ismail Dean, Kulliyyah of Engineering

IV

DECLARATION

I hereby declare that this thesis is the result of my own investigations, except where

otherwise stated. Other sources are acknowledged by footnotes giving explicit

references and a bibliography is appended.

Name: lamaludin lalani

"JLw.eI,,~~l Signature: ... ~i~~ ••••••••••••••••••••

"'1 / % G" Date: ............................ .

v

INTERNATIONAL ISLAMIC UNIVERSITY MALAYSIA

DECLARATION OF COPYRIGHT AND AFFIRMATION OF FAIR USE OF UNPUBLISHED RESEARCH

Copyright © 2005 by lamaludin lalani. All rights reserved.

CONTROL STRATEGIES FOR AUTOMATIC GANTRY CRANE SYSTEM

No part of this unpublished research may be reproduced, stored in a retrieval system, or

transmitted, in any form or by any means, electronic, mechanical, photocopying, recording or

otherwise without prior written permission ofthe copyright holder except as provided below.

1. Any material contained in or derived from this unpublished research may only be used by others in their writing with due acknowledgement.

2. HUM or its library will have the right to make transmit copies (print of electronic) for institutional and academic purposes.

3. The HUM library will have the right to make, store in a retrieval system and supply copies of this unpublished research if requested by other universities and research libraries.

Affirmed by lamaludin lalani

~~~t .L •• ,~~ •••••••••••••••

Signature Date

VI

Jalani Cltulas, Alimah Hamzah, Nllrlll Alwani Atltiralt

Vll

ACKNOWLEDGEMENTS

Alhamdulillah, all praise to Allah, the Most Beneficcnt and the Most Merciful, who has taught what I knew not. It is by the grace of the Almighty Allah that this research work has been completed successfully.

A deepest appreciation is dedicated to Dr Wahyudi Martono for his extraordinary patience and his enduring optimism. I really admire his knowledge, intelligence and patience. I do appreciate his dedicated guidance, suggestion, critical comments and warm support which have given me the opportunity to develop my research skills. I am blessed and honored to be his student.

Also a special thanks to the academic and technical staff of the Mechatronics Engineering Department, International Islamic University, Malaysia. They have assisted me in giving advices, ideas, and technical supports to this research project in the spirit of brotherhood of Islam.

I would like to thank all my friends especially to the fellow brothers in the Research Laboratory who have been keeping the atmosphere of research in the laboratory lively.

Finally, my sincere gratitude goes to my beloved family especially my parents for their love, endless encouragement and D'ua. They are truly my inspiration.

\'111

PUBLICATIONS

1. Jamaludin, Wahyudi, Suhaimi and Iswanaini "Development of Automatic Gantry Crane, Partl: Modeling and Parameters Identification", Proceeding of the Sixth Industrial Seminar (lES 2004) Campus EEPIS-ITS, Surabaya Indonesia, October 12, 2004, pp.306-311.

11. Jamaludin, Wahyudi, Suhaimi and Iswanaini "Development of Automatic Gantry Crane, Part2: Controller Design and Implementation", Proceeding of the Sixth Industrial Seminar (lES 2004) Campus EEPIS-ITS, Surabaya Indonesia, October 12, 2004, pp. 312-315.

Ill. Wahyudi, Jamaludin and Riza Muhida "Mechatronics Design of An Automatic Gantry Crane", Proceeding of International Conference on Product Design & Development ICPDD 2004, Kota Kinabalu Sabah Malaysia, December 20-23,2004, pp. 123-127.

iv. Wahyudi and Jamaludin, "Design and Implementation of Fuzzy Logic Controller for Automatic Gantl)! Crane System", Accepted for the Second International Conference On Mechatronics, Pan Pacific Hotel, Kuala Lumpur Malaysia, May 10-12,2005.

v. Wahyudi and Jamaludin, "Hardware-ill-the-Loop-Simulation (HILS) Based on Designed and Robustness Evaluation of an Intelligent Gantry Crane System", Accepted for International Conference on Control, Automation and System, KlNTEX, Gyeonggi Do, Korea,June 2-5, 2005.

IX

TABLE OF CONTENTS

Abstract (English) ........................................................................ II

Abstract (Arabic) ....... ................................ ...... ............................ III

Approval Page............................................................................ iv Declaration..................................................................... ........... v Copy right Page......... .................................... ............................... VI

Dedication............... .................................................................... VII

Acknowledgements.... ......... ............... ......... ............. ..... ... .. ....... . ... VIll

Publications................................................................................. IX

List of Tables ....... ...... ... ..... ....... ............... ........................... .... .... XII

List of Figures............................................................................. Xlll

List of SyYl1bols............................................................................. xv List of Abbreviations .................................................................. '" XVII

CHAPTER l:INTRODUCTION ............... .......... .......... ........ ............ I 1.1 Background................................................................. I 1.2 Objective ..................................................................... 4 1.3 Methodology............................................................... 4 1.4 Organization of Thesis ...... ............. ........ .......... ........ ................ ..... 5

CHAPTER 2:MODELING AND PARAMETERS IDENTIFICATION ....... 7 2.1 Introduction........................................................... ...... 7 2.2 System Description....................................................... 7 2.3 Modeling and parameters identification........ ................. ....... 9

2.3.1 Mathematical modeling ....................................................... 9 2.3.2 Parameters identification ..................................................... 18

2.4 Experimental setup ......................................................... 23 2.5 Results ........................................................................ 24

2.5. I Parameters identification results ................................ 24 2.5.2 Model validation .................................................. 26

2.6 Conclusion................................................................ 27

CHAPTER 3:DESIGN AND IMPLEMENTATION OF CLASSICAL PID CONTROLLER................................................ ......... 28

3.1 Introduction.................... ............................................ 28 3.2 Proposed controller structure ........................................................... 28 3.3 Controller design ............................................................................. 30

3.3.1 Nonlinear control design (NCD) blockset .................... 30 3.3.2 Parameters optimization result ........................................ 33

3.4 Experimental setup ........................................................ 33 3.5 Results ............................................................................................ 34

3.5.1 System performances .......................................................... 34 3.5.2 Robustness evaluation ......................................................... 40

3.6 Conclusion .................................................................. 42

CHAPTER4:DESIGN AND IMPLEMENTATION OF FUZZY LOGIC CONTROLLER......................................................... ·D

4.1 Introduction ................................................................. 43 4.2 Proposed controller structure ............................................ 43 4.3 Basic concept of fuzzy logic controller............ ..................... 44 4.4 Controller design............ ...... ...................... ........... ...... 45

4.4.1 Membership functions................................. .......... 46 4.4.2 Generated linguistic rules....................................... 49 4.4.3 Fuzzy inference and defuzzification ........................... 56

4.5 Results...................................... ........... ...................... 57 4.5.1 System performances ............................................. 57 4.5.2 Robustness evaluation ........................................... 62

4.6 Conclusion........................................................ ... ....... 63

CHAPTER 5:DESIGN AND IMPLEMENTATION OF NCTF CONTROLLER....................... .................................. 64

5.1 Introduction....................... .................................... ..... 64 5.2 Proposed controller structure.................. .......................... 64 5.3 Basic concept ofNCTF controller ....................................... 65 5.4 Controller design..................................................... ..... 69

5.4.1 NCT determination ................................................ 69 5.4.2 Design of compensator ........................................... 71

5.5 Results....................... ................................... ........ ..... 75 5.5.1 System performances ............................................. 75 5.5.2 Robustness evaluation.............................. .... .... ..... 82

5.6 Conclusion....................... ....................... .................... 83

CHAPTER 6:CONCLUSIONS ....................... ............................. ..... 84 6.1 Conclusions....................... ........................ .............. ..... 84 6.2 Further studies ............................................................... 86

BIBLIOGRAPHy ........................................................................... 87

XI

LIST OF TABLES

Table No. Page

3.1 Initial value ofPID and PD controllers 33

3.2 Parameters ofPID and PD controllers 33

3.3 Positioning performance 39

3.4 Anti-swing performance 40

3.5 Performance due to the length ( /! ) variations 41

4.1 The generated fuzzy rules of position control 49

4.2 The generated fuzzy rules of anti-swing control 51

4.3 Positioning performances 61

4.4 Anti-swing performances 61


5.1 PI compensator parameters design 72

5.2 Comparison of the performances for different compensator to the step input 75

5.3 Positioning performances for NCTF controller 77

5.4 Positioning performances 81

5.5 Anti-swing performances 81


Xli

LIST OF FIGURES

Figure No. Page

1.1 Gantry crane

2.1 Lab-scale gantry crane system 9

2.2 Block body diagram of gantry crane system 10

2.3 Equivalent circuit of the DC motor 13

2.4 Forces on the rack and pinion assembly 15

2.5 Gantry crane model 18

2.6 Step response of unknown system G(s) 19

2.7 Determination ofK] 20

2.8 Determination ofK2 21

2.9 Block diagram of parameters identification of gantry crane model 22

2.10 Serial connection between host and target computers to the gantry crane 23

2.11 Experimental step response of angular velocity of the motor 24

'" 2.12 Functionvl(t)=f[Ko-vu(t)]dt 25

o

'" 2.13 Function v 2 (t)= f[KI-vl(t)]dt 25

o

2.14 Block diagram of obtained transfer function 26

2.15 Measured and simulated responses 27

3.1 Schematic diagram of gantry crane system using PID and PO Controllers 29

3.2 Simplified schematic diagram of gantry crane system 29

3.3 Simulink model 31

3.4 Constraint window before adjustment 31

3.5 Desired performance of position control 32

3.6 Desired performance of anti-swing control 32

3.7 Responses to a 10 em step input 36



3.10 Control signal due to the saturation of the actuator 39

Xlll

3.11 Robustness ofPD controller by simulation 41

4.l Schematic diagram of gantry crane using fuzzy logic controller 44

4.2 Fuzzy controller 45

4.3 Membership function of position control 47

4.4 Membership function of anti-swing control 48

4.5 Illustration of how fuzzy rules can cover all possible positions 50

4.6 Illustration of how fuzzy rules can cover all possible swing angles 53

4.7 Physical movement of the trolley for position control 54

4.8 Physical movement of the trolley for position control 55

4.9 Responses to a 10 cm step input 58

4.l0 Responses to a 40 cm step input 59


4.12 Robustness of the fuzzy logic controller by simulation 62

5.l Schematic diagram of using NCTF and fuzzy logic controller 65

5.2 NCTF control system 66

5.3 NeT and object motion 66

5.4 NCT determination 67

5.5 Simple open-loop response of the gantry crane for NCT determination 70

5.6 Construction ofNCT oflab-scale gantry crane 71

5.7 Responses on phase plane 73

5.8 Responses at different positions 74

5.9 Responses to a 10 cm, 40 cm and 70 cm step input 77

5.l0 Responses to a 10 cm step input 78



5.13 Robustness of the Fuzzy logic controller by simulation 82

xiv

LIST OF SYMBOLS

a j system parameter

a2 system parameter

A curve area

b rack damping coefficient

e error

eb back emf

F summation external forces for linear motion

g gravity

h maximum error rate

current

J mass moment of inertia

J m moment inertia of motor

Jo total of moment inertia

J p moment of inertia of rack-pinion

K kinetic energy

Ko system parameter

Kj artificial system parameter

K2 artificial system parameter

Kd derivative gain

Kj integral gain

Kg gear ratio constant

KjOad

kinetic energy of the load

Km motor constant

Kp proportional gain

Ktrolley kinetic energy ofthe trolley

f. length of the string

L lagrangian

Lind inductance

xv

m inclination of the NCT near origin

m! mass of the trolley

m 2 mass of the load

P potential energy

r pitch radii of rack-pinion

R resistance

t time

T summation external torques for rotational motion

Tm torque

u voltage

U o control input voltage

up difference actual error rate and NCT

u r rated input to the actuator

v velocity of the motor

V L velocity of the load

v steady state velocity ss

V T velocity of the trolley

V LIT velocity of the load relative to the trolley

x displacement

8 angle of the string moves

v maximum operator

/\ minimum operator

S damping ratio

O)n natural frequency

a simplified object parameter

XVI

COA

DAQ

GUI

I/O

N

NB

NCD

NCTF

NS

P

PB

PD

PI

PID

PS

PTP

RTW

TCP/IP

Z

LIST OF ABBREVIATIONS

Centre of Area

Data Acquisition Card

Graphical User Interface

Input/Output

Negative

Negative Big

Nonlinear Control Design

Nominal Characteristic Trajectory Following

Negative Small

Positive

Positive Big

Proportional Derivative

Proportional Integral

Proportional Integral Derivative

Positive Small

Point to Point

Real-Time Workshop

Transmission Control Protocol/Intemet Protocol

Zero

XVll

CHAPTER!

INTRODUCTION

1.1 Background

Crane is a machine for gripping, lifting and moving loads horizontally, as well

as lowering and release the gripper back, Omar (2003). These tasks are performed

with the aid of hoisting mechanism that works as an integral part of the crane. Cranes

are widely used in industry for transporting heavy loads and hazardous materials in

shipyards, factories, nuclear installations and high building constructions. In general,

there are two types of crane namely rotary cranes and gantry cranes. Rotary cranes are

commonly use in shipyard and construction site. This type of crane involves rotation

movement during operation. The typical gantry crane is shown in Figure 1.1.

Figure 1.1: Gantry crane

The gantry crane should move loads as fast as possible without causing any

excessive movement at the final position, thus it can achieve higher productivity. This

type of crane incorporates a trolIey which moves over the jib (girder) and translates in

a horizontal plane. In some cases, the jib is mounted on another set of orthogonal

railings calIed bridge cranes. Furthermore, the payload is attached to the trolIey by a

cable. The length can be varied by hoisting mechanism.

Nowadays, most of the current gantry cranes in industry are open loop systems

which are operated by operators. The operators use joystick to control position in two

directions of vertical and horizontal. When moving it horizontally, a constant

acceleration is generated until the maximum velocity is gained. On the other hand,

moving vertically is only lowering and lifting the cable, therefore the load can be

removed immediately. The joysticks have analog control, which means that the

amplitude of the acceleration can be controlled. When the joystick is released the

trolley decelerates until it stops. Here, the performance of the gantry crane depends on

the skill of the operators. The company that hired the operators needs to train them

properly in order for them to work effectively and safely during gantry crane

operation.

As mentioned earlier, most of the common gantry cranes are open-loop

systems that swing when payload is suddenly stopped after a fast motion. The swing

motion can be reduced and stopped without using the controller. However, it will be

time consuming and eventually reduce the productivity of the gantry crane system.

Even though the skillful operators who operate the crane, they still face some

constraints such as fatigue problem. This phenomenon can cause inconsistent

performance of the gantry crane systems and might cause accident.

2

Various attempts in controlling gantry cranes system based on open loop

system were proposed. For example, open loop time optimal strategies were applied

to the crane by many researchers such as Yamagashi (1974), Sakawa and Shindo

(1981), Manson (1982), Auernig and Troger, (1987). They came out with poor results

because open loop strategy is sensitive to the system parameters (e.g. rope length) and

could not compensate for wind disturbances. Another importance of open loop

strategy is the input shaping introduced by Karnopp (1992), Teo (1998) and Singhose

(1997). Even though they claimed that input shaping is good in controlling the open

loop system but it still faces sensitiveness to the external disturbances and parameter

variations.

On the contrary, feedback control is well known to be less sensitive to

disturbances and parameter variations. Hence, it is an attractive method for crane

control design. Ridout (1989) developed a controller, which feeds back the trolley

position, speed and load swing angle. Through this approach, the system damping can

be changed during the transferring of the load. Many researchers proposed the

controllers based on feedback system. For example Mita and Kanai (1979) proposed

optimal control, Boustany and d'Andrea-Novel (1992) introduced adaptive control,

and Cheng and Chen (1996) have developed linearization techniques. However, in

general closed-loop control systems, it is designed based on the exact model and

parameters of the plant. It is known that the mathematical modeling including

parameters identification is complicated and time consuming due to nonlinearity

dynamics of gantry crane system. Recent work on gantry crane control system was

presented by Omar (2003). The author had proposed PD controller for position

control and three different methods for anti-swing control namely a classical PO

controller, delayed feedback technique and fuzzy logic controller. All these

3

controllers were designed based on mathematical model of the crane except fuzzy

logic controller. However, this fuzzy logic controller uses mapping method which

needs delayed feedback technique before fuzzy logic controller can be designed. This

strategy was time consuming because fuzzy logic controller could not be implemented

directly and relied on other controller to fulfill the design.

The scope of a lab-scale gantry crane system was used in the experimental

study that only considers the planar movement of trolley with fixed load and length of

string. The lifting and unloading of load is not considered and the velocity of the

trolley remains constant. The experimental study was implemented to identify

parameters of the gantry crane system and to examine performances of the controllers.

1.2 Objective

The objective of the study is to investigate the appropriate control method for

gantry crane system. The controller is expected to have simple structure, easy to

design and also robust to the parameter uncertainties.

1.3 Methodology

In order to achieve the objectives of this research, the following procedures

are considered:

1. The research starts with the understanding of the gantry crane background,

analyzes its problems and investigates control theory which has been applied

to the gantry crane system.

ii. A mathematical model of lab-scale gantry crane system is developed.

lll. Investigate the conventional control method (PID and PD controllers) which

has been applied to the gantry crane system.

4

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