Crane motion induces payload oscillation that makes accurate positioning of the payload a challenging task. As the payload size increases, it may be necessary to utilize multiple cranes for better control of the payload position and orientation. However, simultaneously maneuvering multiple cranes to transport a single payload increases the complexity and danger of the operation. This thesis investigates the dynamics and control of dual-hoist bridge cranes transporting distributed payloads. Insights from this dynamic analysis were used to design input shapers that reduce payload oscillation originating from various crane motions. Also, studies were conducted to investigate the effect input shaping has on the performance of human operators using a dual-hoist bridge crane to transport distributed payloads through an obstacle course. In each study, input shaping significantly improved the task completion time. Furthermore, input-shaping control greatly decreased operator effort, as measured by the number of interface button pushes needed to complete a task. These results clearly demonstrate the benefit of input-shaping control on dual-hoist bridge cranes. In addition, a new system identification method that utilizes input shaping for determining the modal frequencies and relative amplitude contributions of individual modes was developed to aid in the dynamic analysis of dual-hoist bridge cranes, as well as other multi-mode systems. This method uses a new type of input shaper to suppress all but one mode to a low level. The shaper can also be used to bring a small-amplitude mode to light by modifying one of the vibration constraints.

<p>Dynamic systems and robotic manipulators designed for time-optimal point-to-point motion are adversely affected by residual vibrations introduced due to the joint flexibility inherent in the system. Over the years, multiple techniques have been employed to improve the efficiency of such systems. While some techniques focus on increasing the system damping to efficiently dissipate the residual energy at the end of the move, several techniques achieve rapid repositioning by developing cleverly shaped input profiles that aim to reduce energy around the natural frequency to avoid exciting the resonant modes altogether. In this work, a numerical framework for constructing shaped inputs using a Versine basis function with peak acceleration constraint has been developed and improvements for the existing numerical framework for the Ramped Sinusoid basis function have been made to extend the range of values of the weighting function and improve the computational time. Performance metrics to evaluate the effectiveness of the numerical framework in minimizing residual vibrations have been developed. The effects of peak input acceleration and weighting function on the residual vibration in the system have been studied. The effectiveness of the method has been tested under multiple conditions in simulations and the results were validated by performing experiments on a two-link flexible joint robotic arm. The simulation and experimental results conclusively show that the inputs developed using the constrained numerical approach result in better residual vibration performance as compared to that of an unshaped input. </p>

During fast point-to-point motion, the inherent joint flexibility could be detrimental in terms of residual vibration. Aiming to minimize the vibration, the command shaping method has been developed so as to remove critical energy from the input profile at resonant frequencies. Since this method requires information of a physical model in order to find the target frequencies, the quality of the shaped command profile relies on the accuracy of the model parameter estimation. Therefore, in this work, a system identification method using Instrumental Variables is applied from the literature. Compared with the classic Ordinary Least Square method, the IV approach has successfully improved the estimation of parameters, based on simulation results. The accuracy of parameter estimation influences the command profile, as does the feedback controller. In this work, starting from a mathematical derivation with a mismatch model due to a feedback controller called Computed Torque Control, insight for the closed-loop system is given with regard to the interaction between control gains and the actual resonant frequencies. It is found that the control gain is able to modify the actual resonant frequency curve, and push it into or out of the shaping bounds which are generated from the command shaping method. Further analysis based on the simulation results shows that the overlap area between the shaping bounds and the actual frequencies affects the level of residual vibration. In light of this fact, an optimal control gain exists and is found when the estimation error is in a certain range. At the end, recommendations for choosing the control gains are provided.

Bridge and gantry cranes are crucially important elements in the industrial complex; they are used in many areas such as shipping, building construction, steel mills, and nuclear facilities, just to name a few. These types of systems tend to be highly flexible in nature, generally responding to commanded motion with oscillations of the payload and hook. The response of these systems to external disturbances, such as wind, is also oscillatory in nature. Often, the oscillations of the hook and payload have undesirable consequences. For instance, precise manipulation of payloads is difficult when cable sway is present. Oscillation of the hook can also present a safety hazard. For these reasons, the ability to successfully negate these detrimental dynamics can result in improved positioning, quicker settling time, and improved safety. This thesis addresses the dynamic properties of bridge and gantry cranes in an effort to develop a control scheme that enables strides to be made in these areas of positioning, efficiency, and safety. The fundamental advancement arising from this thesis is the development of a control scheme that enables precise positioning of the payload while motion and disturbance-induced oscillations are eliminated. A command generation technique uniquely suited for reducing oscillation in low-frequency flexible systems is examined and utilized in the control. The control scheme is implemented on a 10-ton bridge crane for validation purposes.

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 significantly. 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 significantly. 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 filtering technique that reduces motion-induced vibration in oscillatory systems. This thesis develops a dynamics model for a mobile boom crane and analyzes the difficulty of controlling payload oscillation on a boom crane. Input shaping will shown to be effective 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.

The rapid movement of machines is a challenging control problem because it often results in high levels of vibration. As a result, flexible machines are typically moved relatively slowly to avoid such vibration. Therefore, motion-induced vibration limits the operational speed of the system. Input shaping is one method that eliminates motion-induced vibrations by intelligently designing the reference command such that system vibration is cancelled. It has been successfully implemented on a number of systems, including bridge and tower cranes. The implementation of input shaping on cranes provides a substantial increase in the operational efficiency. Unfortunately, most cranes, once erected, have limited or no base mobility. This limits their workspace. The addition of base mobility could help extend the operational effectiveness of cranes and may also expand crane functionality. Mobile cranes may also be better suited for use in harsh and/or distant environments. Teleoperation of oscillatory systems, such as cranes, then becomes another avenue for advancement of crane functionality. Base mobility in cranes presents both additional control challenges and operational opportunities. A crane with base mobility is redundantly actuated (overactuated), such that multiple combinations of actuators can be used to move a payload from one location to another. This opens the possibility for the selection of a combination of actuation that provides both rapid motion and limited system vibration. The extension of input shaping into this operational domain will provide a method to maximize effective actuation combinations. Toward addressing these issues, new multi-input shaping methods were developed and applied to a mobile, portable tower crane. During this development, a firm understanding of robust input shaping techniques and the compromises inherent to input shaper design was formed. In addition, input shaping was compared to other command generation techniques, namely lowpass and notch filtering, and proven to be superior for vibration reduction in mechanical systems. Another, new class of input shapers was also introduced that limit the input shaper induced overshoot in human operated systems. Finally, a series of crane operator studies investigated the application of input shaping techniques to teleoperated cranes. These studies suggested that input shaping is able to dramatically improve remote crane operator performance.

Recent decades have been witness to explosive leaps in manufacturing productivity. Advances in communication technology, computing speed, control theory, and sensing technology have been significant contributors toward the increased productivity and efficiency that industry has exhibited. The continued growth of technological equipment and engineering knowledge challenges engineers to fully utilize these advancements in more sophisticated and useful automation systems. One such application involves enhancing bridge and gantry crane operation. These systems are used throughout the globe, and are critical aspects of industrial productivity. Consequently, improving the operational effectiveness of cranes can be extremely valuable. Effective control of cranes can be largely attributed to two distinct, but related aspects crane manipulation: 1) the expertise of operators, which are responsible for issuing commands to the structures, and 2) the dynamic properties of cranes, which influence how the structures respond to issued commands. Accordingly, the operational efficiency of cranes can be influenced by changing both the way that operators issue commands to cranes, and also how the crane responds to issued commands. This thesis is concerned with dynamic control theory of flexible machines, and human/machine interaction, especially as these areas relate to industrial crane control. In the area of dynamic control, this thesis investigates control strategies that are specifically suited for use on systems that possess common actuator nonlinearities, like saturation, rate limiting, dead-zone, backlash, and finite-state actuation. In the area of human/machine interaction, this thesis investigates the effects of different crane interface devices on the operational efficiency of cranes.