International Journal of Applied Engineering Research

ISSN 0973-4562 Vol.2, No.1 (2007), pp. 147161

Research India Publications
http://www.ripublication.com/ijaer.htm



Sensorless Anti-swing Control for Automatic Gantry
Crane System: Model-based Approach


Mahmud Iwan Solihin

and Wahyudi*

Intelligent Mechatronics System Research Group
Department

of Mechatronics Engineering
International Islamic University Malaysia, P.O. Box 10. 50728
Kuala Lumpur, Malaysia. E-mail: iwan.mahmud@yahoo.com
*Correspondence Author E-mail: wahyudi@iiu.edu.my


Abstract

To achieve a good control performance of automatic gantry crane system,
sensors are indispensable instrument for feedback signals. However, sensing
the payload motion of a real gantry crane, particularly swing motion, is
troublesome and often costly. Therefore, sensorless anti-swing controls for
automatic gantry crane system are proposed in this paper. The proposed
sensorless anti-swing controls are based on mathematical model of the crane
based on two approaches. First, a soft sensor based on mathematical model of
the crane is introduced to substitute the real swing sensor. In this method, the
swing motion of the payload is estimated based on the mathematical model
from the measured trolley position. Second, a reference modifier is introduced
to produce anti-swing trajectory while performing trolley positioning. An
experimental study using lab-scale automatic gantry crane is carried out to
evaluate the effectiveness of the proposed sensorless anti-swing controls. The
results show that both proposed sensorless anti-swing controls are effective for
payload swing suppression since it gives similar performance to the sensor-
based anti-swing control. Moreover, the proposed methods are also robust to
deal with parameter variations. However, the first method has better
performance than the second method.

Keywords: anti-swing, gantry crane, model-based, sensorless.


Introduction
Cranes are widely used in various applications such as heavy loads transportation and
hazardous materials handling in shipyards, in factories, in nuclear installations and in
high building constructions. Gantry crane is a common type of cranes used to transfer
148 Mahmud Iwan Solihin

and Wahyudi
the payload from one position to desired position. A gantry crane incorporates a
trolley which moves along the track and translates in a horizontal plane.
In gantry crane system, the load suspended from the trolley by cable is subject to
swing caused by improper control input and disturbances. The failure of controlling
crane may cause accident and may harm people and the surroundings. Therefore, the
gantry crane control must be able to move the trolley adequately fast and to suppress
the payload swing at the final position. This is so-called anti-swing control.
Various attempts of anti-swing control for automatic gantry crane have been
proposed. Singhose et al., [1] and Park et al., [2] adopted input shaping technique
which is open loop approach. However, these methods could not damp the residual
swing well. Gupta and Bhowal [3] also presented simplified open-loop anti-swing
technique. They have implemented this technique based on velocity control during
motion. Other notable researches into time-optimal open-loop control have also been
done by Manson [4] and also by Auernig & Troger [5] to control an overhead crane
with hoisting. However these are still open-loop approach which is sensitive to system
parameters.
On the other hand, feedback controls which are well known to be less sensitive to
parameter variations and disturbances have also been proposed in some researches
varying from conventional PID (proportional + integral + derivative) to intelligent
approaches. Omar [6] proposed PD controls for both trolley position and swing
suppression. Nalley & Trabia [7] adopted fuzzy logic control to both positioning
control and swing damping. Similarly, Lee & Cho [8] proposed feedback control
using fuzzy logic. A fuzzy logic control system with sliding mode control concept
was also developed for an overhead crane system by Liu et al. [9]. Furthermore, a
fuzzy-based intelligent gantry crane system has also been proposed by Wahyudi &
Jalani [10]. The proposed fuzzy logic controllers consist of position as well as anti-
swing controllers. The performance of the proposed intelligent gantry crane system
had been evaluated experimentally on a lab-scale gantry crane. It was shown that the
proposed system has a good positioning performance as well as a good capability to
suppress the swing angle in comparison with the crane controlled by the PID
controllers.
However, most of the feedback control system proposed needs sensors for
measuring the trolley position as well as the load swing motion. In addition, designing
the swing measurement of the real gantry crane system, in particular, is not an easy
task since there is a hoisting mechanism on parallel flexible cable. Altafini et al. [11]
presented a method using measurements of electrical torque and angular velocity of
the drives for dynamic load observer. However, it used instead two additional sensors
to observe swing angle by knowing the length of the cable.
Some researches have also focused on control schemes with vision system that is
more feasible because the vision sensor is not located at the load side. The more
recent feedback control using CCD camera was also successfully done by Lee et al.
[12] and Osumi et al. [13]. The drawbacks of the vision system, among those are
difficult maintenance and high cost [14].
To overcome this problem, sensorless anti-swing control strategies are developed
and proposed for automatic gantry crane system. The proposed methods are based on
Sensorless Anti-swing Control 149
mathematical model of the crane. The real sensor measuring load swing angle is
physically omitted in the proposed methods. There are two approaches to achieve the
sensorless anti-swing control strategies. In the first method, a soft sensor based on
mathematical model of the crane is introduced to substitute the real swing sensor. In
this method, the motion of the payload is estimated based on the dynamic model from
the measured trolley position. In the second method, a reference modifier is
introduced to produce anti-swing trajectory while performing trolley positioning.
In order to evaluate the effectiveness of the proposed methods, experimental study
is carried out on a lab-scale gantry crane and their performances are compared with
that of sensor-based anti-swing control. The experimental result has shown that the
proposed sensorless anti-swing controls are effectively used to suppress the swing
motion of the payload since they give similar performance to that of sensor-based
anti-swing control well. Furthermore, robustness of the proposed methods to
parameter variations is also studied experimentally. It has been shown through
experiment that the proposed methods are also robust to parameter variations (i.e.
rope length). However, the first method is better than the second method in their
performances.


Basic Concept of Sensorless Anti-Swing Control
Most of automatic gantry crane controls proposed by researchers use two controllers
as shown in Figure 1, for controlling both trolley position and swing of the crane
payload. As no-swing motion of the payload is required, the schema of the feedback
system for automatic gantry crane can be simplified as shown in Figure 2. In this
feedback control system, two sensors are needed to measure the trolley position
) s ( X and swing angle ) s ( . However as discussed previously, swing angle
measurement of the real gantry crane system, in particular, is not a simple task.


T rolley position
sensor
+
-
AUTOMATIC
GANTRY
CRANE
+
+
P osition
contr oller
Swing
contr oller
X
r
( s)
Swing angle
sensor
COMPUTER
X( s)
(s)
+
( s) =0
-


Figure 1: Diagram of anti-swing feedback control


150 Mahmud Iwan Solihin

and Wahyudi
T rolley position
sensor
+
-
AUTOMATIC
GANTRY
CRANE
+
+
P osition
controller
Swing
controller
X
r
( s)
Swing angle
sensor
COMPUTER
X(s)
(s)


Figure 2: Simplified diagram of anti-swing feedback control


T r olley position
sensor
+
-
AUTOMATIC
GANTRY
CRANE
+
+
P osition
contr oller
Swing
contr oller
X
r
(s)
Soft
sensor
COMPUTER
X( s)


Figure 3: Proposed sensorless anti-swing control 1


Therefore, sensorless anti-swing controls are proposed. This can be achieved by
two different approaches. First, swing angle is estimated. This is done by soft sensor
approach. A soft sensor or virtual sensor is basically a system model designed to
substitute the momentary or permanent unavailability of a real sensor in the controlled
object [15]. A model-based soft sensor is adopted to estimate the swing motion.
Therefore, mathematical model of the crane is needed. This will be called as
Sensorless 1 throughout the paper and the schematic diagram is shown in Figure 3.
Second, reference input is modified in order to suppress the payload swing. The
modified reference input produces trajectory such that the trolley moves from a point
to another point without causing an excessive swing motion of the payload. The
mathematical model of the crane system including the characteristic of oscillation is
also required to generate the modified reference input. The control diagram is shown
in Figure 4. This will be named as Sensorless 2.
Sensorless Anti-swing Control 151

T rolley position
sensor
+
-
AUTOMATIC
GANTRY
CRANE
P osition
controller
Reference
modifier
COMPUTER
X(s)
X
r
(s)
mod
r
X

Figure 4: Proposed sensorless anti-swing control 2


Mathematical Model
In this paper, the proposed methods are designed based on mathematical model.
Mathematical model of gantry crane is derived using Lagrange equations. The model
includes also the DC motor dynamic as actuator. Figure 5 shows the simplified
diagram of trolley crane mechanism. The position of swinging payload suspended by
cable with respect to horizontal and vertical reference, respectively x
m
and y
m
, can be
represented as:
sin l x x
m
+ = (1)
cos l y
m
= (2)


m
2
x
l
F
O
T

m
1
x
m

Figure 5: Trolley crane model
The Lagrange equation is developed from derivation of kinetic and potential
energy. For simplicity, some assumptions are made. Friction force existing in the
trolley is neglected; the cable elongation due to tension force is also neglected. By
regarding x and as the generalized coordinates, the Lagrange equations associated to
linear and rotational motion are:
F ) sin cos ( l m x ) m m (
2
1 2 1
= + +

(3)
152 Mahmud Iwan Solihin

and Wahyudi
0 sin g cos x l = + +

(4)
where F is the summation of all external forces for linear motion and T is the
summation of all external torques in rotational motion.
The linearization can be done by considering the swing angle is kept small during
control so that sin and 1 cos . As a result, (3) and (4) can be written as:
F l m x ) m m (
1 1 2
= + +

(5)
0 g l x = + +

. (6)
The translational motion of trolley is driven by DC motor. To obtain the entire
model of lab-scale crane, the motor dynamic is modelled according to equivalent DC
motor circuit. The motor torque, T, is proportional to armature current, i and the back
emf voltage proportional to rotational velocity, &.
i . K T
t
= (7)

m e e b
K K e

= = . (8)
The equivalent circuit has armature resistance, R and inductance, L. According to
Kirchhoffs law, the relationship between voltages and current can be expressed as
follows:

b
e
dt
di
L i . R V + + = . (9)
The crane system consists of pulleys mechanism to transfer rotational torque of
motor shaft to translational trolley motion. With r denotes radius of pulley, J is total
moment of inertia and b represents friction constant, the total torques can be
summarized.

m m t
J Fr b i K

= . . (10)
Finally, (5)-(10) can be combined in the form of the following transfer functions:

) 1 s a s a ( s
k
) s ( U
) s ( X
1
2
2
0
+ +
= (11)

g ls
s
) s ( X
) s (
2
2
+

(12)
where:

Rb K K
r K
k
t e
t
0
+
= (12.a)

Rb K K
LJ r Lm
a
t e
2
2
2
+
+
= (12.b)
Sensorless Anti-swing Control 153

Rb K K
Lb RJ r Rm
a
t e
2
2
1
+
+ +
= . (12.c)

Development of Model-based Sensorless Anti-swing Control
A. Sensorless 1
A model-based soft sensor is proposed to provide output estimation of the payload
swing. The schematic diagram is shown in Figure 6, the dynamic information from
trolley position ) s ( X is given to the model-based soft sensor. The model-based soft
sensor produces output estimation of the payload swing that will be used for feedback
signal to the controller. Consequently, linearized dynamic equation expressed in (6) is
used as model-based soft sensor. The swing angle of payload is estimated by using the
following:
) s ( X
g ls
s
) s (

2
2
+

= (13)
where ) s ( and ) s ( X are estimated swing motion of the payload and trolley motion
in Laplace domain respectively.


Trolley position
sensor
+
-
AUTOMATIC
GANTRY
CRANE
+
+
Position
controller
Swing
controller
X
r
(s)
COMPUTER
X(s)
(s)
g ls
s
+

2
2
soft sensor

Figure 6: Sensorless anti-swing control 1

B. Sensorless 2
In this method, the controller should produce command input that guarantee the
positioning performance while cancelling the payload oscillation especially during
acceleration/deceleration. This can be achieved by modifying the input reference. In
order to develop modified reference input, according to (6), there is linearized
relationship between swing angle and trolley acceleration as follows:
x g l

= + . (14)
Moreover, by differentiating both sides of (1), the following is obtained:


l x x
m
= . (15)
Then, (15) is substituted to (14) resulting in the following equation:
154 Mahmud Iwan Solihin

and Wahyudi

0 x
l
g
x
l
g
x
m m
= +
. (16)
By assuming the feedback control system of Figure 4 has a high bandwidth so that
) s ( X ) s ( X
mod
r
= , (16) becomes:
) s ( X
s
) s ( X
mod
r
l
g
l
g
m
2
+
= (17a)
) s ( X
s
) s ( X
m
l
g
l
g 2
mod
r
+
= . (17b)
Lets assume there is no input modifier ( ) s ( X ) s ( X
mod
r r
= ), (17a) can be written
as:
) s ( X
s
) s ( X
r
l
g
l
g
m
2
+
= . (18)
Equation (18) shows a second order system without damping which gives an
oscillation response of the payload position X
m
(s) for any input reference X
r
(s).
Theoretically, the oscillatory motion can be suppressed by adding enough damping
ratio. To add the damping factor to the system, a reference modifier with modifier
parameter K is inserted to the system so that (18) becomes:
) s ( X
Ks s
) s ( X
r
l
g
l
g
m
2
+ +
= . (19)
Equation (19) may be written in standard second order system as follows:
) s ( X
s 2 s
) s ( X
r
2
n n
2
n
m
2

+ +
= (20)
where:

l
g
n
= (20.a)

n
2 K = . (20.b)
Then, by combining (17a) and (19), the relationship between the original
reference input ) s ( X
r
with the modified reference input ) s ( X
mod
r
can be obtained as
follows:
) s ( X
s
Ks
) s ( X ) s ( X
mod
r
l
g
mod
r r
2
+
+ = . (21)
Substituting ) s ( X
mod
r
in the second term of (21) by (17b), yields:
Sensorless Anti-swing Control 155
) s ( X s
g
Kl
) s ( X ) s ( X
m
mod
r r
+ = . (22)
By using (14) and (15), (22) is re-written to the following form:

s
) s (
Kl ) s ( X ) s ( X
mod
r r

= . (23)
Finally, (12) is used to modify (23) becomes:
) s ( X
s
s
K ) s ( X ) s ( X
l
g 2
r
mod
r

+
= . (24)
Figure 7 shows the diagram of the proposed sensorless anti-swing control
developed using (24). The proposed modifier parameter K is obtained based on the
added damping ratio and the natural frequency
n
as shown in (20).


z
+
_
+
_
) ( s X
r
) (
mod
s X
r
Position
controller
AUTOMATIC
GANTRY
CRANE
X (s)
COMPUTER
l
g
s
s K
+
2
.
Trolley position
sensor


Figure 7: Sensorless anti-swing control 2.

Results
A System Description
In order to evaluate the performances of the proposed sensorless anti-swing controls,
the proposed methods are implemented to control a lab-scale gantry crane system
shown in Figure 8 together with its diagram as shown in Figure 9. The designed lab-
scale gantry crane system has four main parts that are trolley system, body frame,
potentiometers and a DC motor as an actuator. The DC motor and its driver are used
to move the trolley. The DC servo driver circuit operates the motor in the velocity
control mode. The input voltage reference between -10.0 volts to 10.0 volts is sent
from the PC to drive a 6W, 12V DC motor as control signal for trolley position. To
detect trolley position and payload swing angle, 10kO 10-turns and
3
/
4
-turns
156 Mahmud Iwan Solihin

and Wahyudi
potentiometers are installed respectively. Noise filters are also included to reduce
noisy signals from the potentiometers/sensors. This is done by digital filtering in the
PC. The proposed method is implemented digitally on a personal computer and is
operated with 1 ms sampling time. The MathWork's MATLAB/Simulink is used for
real-time controller implementation through RTW and xPC Target. The experimental
setup is shown in Figure 10.




Figure 8: Lab-scale gantry crane.
o o
m
2
l
O
m
1
Motor
O
80 cm


Figure 9: Diagram of gantry crane.
CRANE SYSTEM
Host PC-MATLAB Target PC
Serial-RS232
DAQ Card
CRANE SYSTEM
DC servo
Swing angle
sensor
Trolley position
sensor
SIMULINK-
XPC Target


Figure 10: Experimental setup.
Sensorless Anti-swing Control 157
Table 1: List of parameters.

Parameter Description Value
m
1
Trolley mass 0.25 kg
m
2
Payload mass 1 kg
l Cable length 60 cm
g Gravitational acceleration 981 cm/s
2

r Radius of pulley 2 cm

The proposed sensorless anti-swing controls are based on mathematical model of
the crane, a mathematical model of the lab-scale gantry crane was developed. Table 1
lists the known parameter values of the system. Since not all parameters are known to
obtain the transfer function model of the system, the unknown parameter of the
transfer function was identified using integral step response [16]. Detail of the transfer
function identification for gantry crane system was discussed in [17]. The obtained
model of the crane is as follows:

1 s 234 . 0 s 016 . 0
12 . 20
) s ( U
) s ( X
2
+ +
= (25)

981 s 60
s
) s ( X
) s (
2
2
+

. (26)
B. Controller Design
Well-known classical PID controllers are designed and used to evaluate the
effectiveness of the proposed sensorless anti-swing controls. The function of the
controller is to control the payload position ) s ( X so that it moves to the desired
position ) s ( X
r
as fast as possible without excessive swing angle ) s ( . Due to its
simplicity, a PID controller is adopted to control the trolley position, while a PD
controller is used for anti-swing controller. The PID controller gains are designed and
optimized with simulation model by using Simulink response optimization library
block. It is a numerical time domain optimizer developed under MATLAB/Simulink
environment. Hence the Simulink response optimization library block assists in time-
domain-based control design by setting the desired overshoot, settling time and steady
state error.
In order to realize fast motion with small overshoot, the PID controller is
optimized by considering the following desired specifications:
Overshoot _ 2
Settling time _ 5 s
Steady state error _ +1
Moreover, in order to suppress the swing angle quickly, the PD controller is
optimized based on the following desired specifications:
Settling time _ 5 s
Residual swing _ +0.05 rad.
Table 2 lists the obtained PID controller parameters as the result of optimization
using Simulink response optimization library block.
158 Mahmud Iwan Solihin

and Wahyudi
Table 2: PID controller parameters.

Controller Gains
Position control Anti-swing control
Proportional, K
p
0.17 13.54
Integral, K
i
-1.67x10
-4
-
Derivative, K
d
0.07 -0.33

Sensorless 2, particularly, requires only PID position control. The same PID gains
are used. Moreover, the parameter K has to be designed based on the damping ratio
added to the system. Whilst the suitable value of design parameter K can be evaluated
to obtain the best performance, with known parameters of model, l=60cm and
g=981cm/s
2
, thus &
n
=4.04 rad/s. The selection of K value theoretically corresponds
to the damping ratio which affects the settling time of oscillation to diminish. In this
paper an additional damping ratio of = 0.4 is added to the system. Based on (20b),
the parameter K of 3.2 is obtained and used in Sensorless 2.

C. Performance Evaluation
The performances of the proposed sensorless anti-swing control methods are
compared with those of sensor-based anti-swing control (Sensor-based). The
positioning performances are evaluated in term of overshoot, settling time and error.
Whilst swing performances are evaluated based on maximum swing amplitude and its
settling time.
Figure 11(a) shows the position responses to a 70 cm step input reference while
Table 3 lists the detail positioning performance comparison. Figure 11(a) and Table 3
show that the positioning performance of the both Sensorless 1 and Sensorless 2 are
similar to those of Sensor-based. In fact, they use same position sensor to detect the
trolley motion. However, the use of the input modifier in Sensorless 2 degrades
system accuracy since the error is larger than that of Sensor-based system. Further
study has to be done to eliminate the negative effect of the reference input modifier to
positioning performance.
Figure 11(b) shows the swing angle responses to a 70 cm step input reference
while Table 4 lists the detail anti-swing performance comparison. Figure 11(b) and
Table 4 show that the anti-swing performances of Sensorless 1, Sensorless 2 and
Sensor-based are also similar each other. Therefore, it can be concluded that the
proposed model-based sensorless methods can be used effectively for sensorless
swing suppression.


Table 3: Positioning performance comparison.
Controller Performance
Sensor-based Sensorless 1 Sensorless 2
Overshoot (%) 0 0 0
Settling time (s) 2.7 2.8 4.0
Error (cm) 0.77 0.69 2.60


Sensorless Anti-swing Control 159
Table 4: Anti-swing performance comparison.
Controller Performance
Sensor-based Sensorless 1 Sensorless 2
Amplitude (rad) 0.25 0.22 0.23
Settling time (s) 3.9 4.6 5.6

0 2 4 6 8 10
0
20
40
60
80
P
o
s
i
t
i
o
n

(
c
m
)
Time (s)
Sensor-based
Sensorless 1
Sensorless 2

(a). Trolley motion
0 2 4 6 8 10
-0.2
-0.1
0.0
0.1
0.2
S
w
i
n
g

(
r
a
d
)
Time (s)
Sensor-based
Sensorless 1
Sensorless 2

(b). Payload swing motion
Figure 11: Experimental Responses to a 70 cm step input reference.


D. Robustness Evaluation
The proposed methods are designed based on the model assumption of fixed cable
length and accurate measurement of the cable length. However, in practice, this
assumption works when hoisting mechanism is considered only for lifting and
lowering the load at initial and final position respectively. This means hoisting is not
performed during gantry motion. In addition, inaccurate measurement of cable length
may also exits. Therefore, if one expects that the anti-swing works also for varying
cable length, the control strategy must be able to deal with.
In order to evaluate the robustness of the proposed methods, a series of
experiment using is carried in which the cable length of the crane is varied 10% of
the nominal length. Figures 12-13 show the swing angle motion of the payload.
According to Figures 12-13, it is shown that there are no much different swing motion
for different cable length for both methods. The performances of the proposed
methods do not change significantly due to cable length variation. Hence it can be
concluded that the proposed model-based sensorless anti-swing controls are robust to
small parameter variation (i.e. cable length). However, it seems that Sensorless 1 is
more robust than Sensorless 2. In other word, Sensorless 2 is more sensitive to cable
length variation than Sensorless 1.
160 Mahmud Iwan Solihin

and Wahyudi
0 2 4 6 8 10
-0.2
-0.1
0.0
0.1
0.2
S
w
i
n
g

(
r
a
d
)
Time (s)
l=55
l=60
l=65

Figure 12: Swing motion for different cable length (Sensorless 1)

0 2 4 6 8 10
-0.2
-0.1
0.0
0.1
0.2
S
w
i
n
g

(
r
a
d
)
Time (s)
l=55
l=60
l=65

Figure 13: Swing motion for different cable length (Sensorless 2)


Conclusion
In the real application of gantry crane, the use of sensors on the load side is
impractical, particularly swing angle sensor. Therefore, sensorless approaches of
swing suppression are proposed in this paper. In the first method, a model-based soft
sensor is developed to substitute real swing angle sensor. There are no sensors on the
payload side. Instead, the swing motion of the payload is estimated based on the
dynamic model of the crane and the trolley position. In the second method, a
reference input modifier is introduced to eliminate real swing angle sensor for
automatic gantry crane so that sensorless anti-swing control is also realized. The
swing motion of the crane is suppressed by modifying the reference input to the
position control system. Implementation of the proposed method on a lab-scale gantry
crane confirmed the effectiveness of the proposed methods. It is also confirmed
through experiment that that the proposed methods are robust to parameter variations.
However, in general, the first method is better than second one in the sense that the
error is smaller and more robust to cable length variation.

Acknowledgment
This research is financially supported by Ministry of Science, Technology and
Innovation (MOSTI) Malaysia under eSciencefund Grant 03-01-08-SF0037.
Sensorless Anti-swing Control 161
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