Adaptive output-based command shaping for sway control of a 3D overhead crane with payload hoisting and wind disturbance

Abstract Payload hoisting and wind disturbance during crane operations are among the challenging factors that affect a payload sway and thus, affect the crane’s performance. This paper proposes a new online adaptive output-based command shaping (AOCS) technique for an effective payload sway reduction of an overhead crane under the influence of those effects. This technique enhances the previously developed output-based command shaping (OCS) which was effective only for a fixed system and without external disturbances. Unlike the conventional input shaping design technique which requires the system’s natural frequency and damping ratio, the proposed technique is designed by using the output signal and thus, an online adaptive algorithm can be formulated. To test the effectiveness of the AOCS, experiments are carried out using a laboratory overhead crane with a payload hoisting in the presence of wind, and with different payloads. The superiority of the method is confirmed by 82% and 29% reductions in the overall sway and the maximum transient sway respectively, when compared to the OCS, and two robust input shapers namely Zero Vibration Derivative-Derivative and Extra-Insensitive shapers. Furthermore, the method demonstrates a uniform crane’s performance under all conditions. It is envisaged that the proposed method can be very useful in designing an effective controller for a crane system with an unknown payload and under the influence of external disturbances.