Heavy-lifting machines such as cranes are widely used at ports, construction sites, and manufacturing plants in a variety of material-transporting applications. However, cranes possess inherent flexible dynamics that make fast and precise operation challenging. Most cranes are driven by human operators, which adds another element of complexity. The goal of this thesis is to develop controllers that allow human operators to easily and efficiently control machines with flexible dynamics. To improve the ease of human operation of these machines, various control structures are developed and their effectiveness in aiding the operator are evaluated. Cranes are commonly used to swing wrecking balls that demolish unwanted structures. To aid the operator in such tasks, swing-amplifying controllers are designed and their performance are evaluated through simulations and experiments with real operators. To make maneuvering of these machines in material-transporting operations easier, input-shaping control is used to reduce oscillation induced by operator commands. In the presence of external disturbances, input shaping is combined with a low-authority feedback controller to eliminate unwanted oscillations, while maintaining the human operator as the primary controller of the machine. The performance and robustness of the proposed controllers are thoroughly examined via numerical simulations and a series of experiments and operator studies on a small-scale mobile boom crane and a two-ton dual-hoist bridge crane.

Mobile boom cranes are used throughout the world to perform important and dangerous manipulation tasks. Given their mobility, these types of cranes can quickly be moved into position. Generally, their base is then fixed and stabilized before they start lifting heavy materials. The usefulness of these cranes can be greatly improved if they can utilize their mobile base during the lifting and transferring phases of operation. This ability greatly expands the workspace by combining base motion with the rotation, lifting, and luffing motions. Of course, the cranes lose some stability margin when a payload is attached. The stability is further degraded when the payload swings. This Master's Thesis presents a stability study of such cranes. As a first step, a static stability analysis of a boom crane is conducted in order to provide basic insights into the effects of the payload weight and crane configuration. Then, a semi-dynamic method is used to take the payload swing into account. As a final step, the results of a dynamic stability analysis obtained by using a multi-body simulation of the boom crane are compared to the outcomes of the previous approaches. This provides conclusions for the practical application of stability analysis. A control method that limits payload swing, and thereby improves stability, is also presented.

The seismic behavior of port container cranes has been largely ignored-by owners, operators, engineers, and code officials alike. This is despite their importance to daily port operations, where historical evidence suggests that port operational downtime following a seismic event can have a crippling effect on the affected local, regional, and national economies. Because the replacement time in the event of crane collapse can be a year or more, crane collapse has the potential to be the "critical path" for post-disaster port recovery. Since the 1960's, crane designers allowed and encouraged an uplift response from container cranes, assuming that this uplift would provide a "safety valve" for seismic loading; i.e. the structural response at the onset of uplift was assumed to be the maximum structural response. However, cranes have grown much larger and more stable such that the port industry is now beginning to question the seismic performance of their modern jumbo container cranes. This research takes a step back, and reconsiders the effect that uplift response has on the seismic demand of portal-frame structures such as container cranes. A theoretical estimation is derived which accounts for the uplift behavior, and finds that the "safety valve" design assumption can be unconservative. The resulting portal uplift theory is verified with complex finite element models and experimental shake-table testing of a scaled example container crane. Using the verified models, fragility curves and downtime estimates are developed which characterize the risk of crane damage and operational downtime for three representative container cranes subjected to a range of earthquakes. This research demonstrates that container cranes designed using previous and current standards can significantly contribute to port seismic vulnerability. Lastly, performance-based design recommendations are provided which encourage the comparison of demand and capacity in terms of the critical portal deformation, using the derived portal uplift theory to estimate seismic deformation demand.

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.

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.

A comprehensive study on berth and quay crane scheduling problems at container terminals at seaports is provided. Problems related to both multi-user terminals, where the terminal operator and liner carriers are different parties, and dedicated terminals, where liner carriers lease the terminal, are considered. A lower bound and an effective meta-heuristic algorithm are proposed for a dynamic variant of the Berth Allocation Problem (BAP). The Multiple Berth Allocation Problem (MBAP) is also introduced. Different crane scheduling methods used by terminal operators are analyzed and a tabu search algorithm is designed for a new variant of the Quay Crane Scheduling Problem (QCSP). The Simultaneous Berth and Quay Crane Scheduling Problem (BQCSP) is introduced with a lower bound analysis and an efficient solution method. A computational analysis is performed which exposes the substantial benefit of simultaneous planning over the hierarchical approach currently used by terminal operators. The tactical level Voyage and Berth Scheduling Problem (VBSP) is defined and a mathematical model based on multi-commodity network flow is presented. Constraints related to transshipments, terminal time windows and service level requirements are incorporated into the model, and how to modify instance data to increase schedule reliability is discussed.

A helicopter can be used to transport a load hanging from a suspension cable. This technique is frequently used in construction, firefighting, and disaster relief operations, among other applications. Unfortunately, the suspended load swings, which makes load positioning difficult and can degrade control of the helicopter. This dissertation investigates the use of input shaping (a command-filtering technique for reducing vibration) to mitigate the load swing problem. The investigation is conducted using two different, but complementary, approaches. One approach studies manual tracking tasks, where a human attempts to make a cursor follow an unpredictably moving target. The second approach studies horizontal repositioning maneuvers on small-scale helicopter systems, including a novel testbed that limits the helicopter and suspended load to move in a vertical plane. Both approaches are used to study how input shaping affects control of a flexible element (the suspended load) and a driven base (the helicopter). In manual tracking experiments, conventional input shapers somewhat degraded control of the driven base but greatly improved control of the flexible element. New input shapers were designed to improve load control without negatively affecting base control. A method for adjusting the vibration-limiting aggressiveness of any input shaper between unshaped and fully shaped was also developed. Next, horizontal repositioning maneuvers were performed on the helicopter testbed using a human-pilot-like feedback controller from the literature, with parameter values scaled to match the fast dynamics of the model helicopter. It was found that some input shapers reduced settling time and peak load swing when applied to Attitude Command or Translational Rate Command response types. When the load was used as a position reference instead of the helicopter, the system was unstable without input shaping, and adding input shaping to a Translational Rate Command was able to stabilize the load-positioning system. These results show the potential to improve the safety and efficiency of helicopter suspended load operations.