MODEL GANTRY CRANE WITH DYNAMIC FEEDBACK SWING CONTROL. NUR SYAHIRAN BIN NORDIN This report is submitted in partial fulfillment of the requirements for the award of Bachelor of Electronic Engineering (Industrial Electronics) With Honours Faculty of Electronic and Computer Engineering Universiti Teknikal Malaysia Melaka May 2008ABSTRACT The use of gantry crane system for transporting payload is very common in industrial application. However, moving the payload using the crane is not easy task especially when strict specifications on the swing angle and on the transfer time need to be satisfied. To overcome this problem, an intelligent gantry crane system had been introduced. Dynamic feedback swing controller is designed for the gantry position and speed, as well as the load angle and angular velocity in order to move the payload of uncertain mass as quickly, accurately, and safely as possible. Responses of the position of the trolley and sway angle of the mass are presented by using SIMULINK in MATLAB software.viii ABSTRAK Pengunaan system “gantry crane” untuk membawa sesuatu beban adalah perkara asas atau kebiasaan didalam bidang industri. Walaubagaimanapun, untuk ‘membawa sesuatu beban atau barang dengan mengunakan “crane” bukanlah sesuatu tugas yang mudah, terutama sekali bila mana sudut ayunannya dan juga masa pemindahannya perlu dititikberatkan. Untuk menghadapi masalah ini, pelbagai system “gantry crane” yang bijaksana telah direkacipta, Pengawal ayunan berkonsepkan suap balik telah direkabentuk bagi mengawal kedudukan “gantry” dan kelajuannya seperti megambil kira dan mengkaji sudut ayunan bebandan sudut pecutannya dengan harapan “gantry” ini dapat membawa beban tertentu dengan pantas, tepat, dan selamat yang mungkin. Tindak balas bagi kedudukan troli dan sudut ayunan beban akan ditunjukkan dengan menggunakan SIMULINK yang terdapat didalam perisian MATLAB.CHAPTER I INTRODUCTION 1.1 Project Introduction The industrial use of gantry cranes is ever increasing, with a demand for greater safety and faster transfer of loads. The uncontrolled pendulum motion of loads suspended from gantry crane endangers both the operating personal and the often fragile load being transported. The operator, by skillful manual drive of the gantry controls, ensures that this unavoidable pendulum motion subsides as quickly as possible, since extended loading and unloading time costly. Increasingly however, relatively high speed operating condition mean that manual suppression of load swing by the operator is not possible, so alte: mechanical or control engineering solutions have be found. Mechanical solutions such as cable bracing or scissor action systems are extremely expensive to install and maintain. Active crane swing composition, on the other hand is a relatively inexpensive means of achieving greater safety and faster transfer of loads.2 In many machines, load positioning is achieved by using the closed-loop control system, However, most of the common gantry cranes result in a swing motion when payload is suddenly stopped after a fast motion. The swing motion can be reduced but will be time consuming i.e. reduce the facility availability as well as productivity. Moreover, the gantry crane needs a skillful operator to control manually based on his or her experiences to stop the swing immediately at the right position. Furthermore to unload, the operator has to wait the stop from swinging. The failure of controlling crane s have also might cause accident and may harm people and surrounding. Many sol been proposed to reduce swing angle by using the dynamic feedback swing control technique. This project will focus on closed loop control system based on the dynamic model of the gantry crane of relatively fixed coefficients of gantry mass and friction. The controller algorithm is that of a state variable feedback system, where gantry position and speed as well as cable angle and angular velocity are fed back as state variables to be controlled and/or regulated. The controller is implemented on small scale gantry crane designed. 12 Objective of Project The main objective of this project is to design a model gantry crane system with dynamic feedback swing control method that will drive the system from initial position into a target position without vibration and reducing swing angle.1.3 Problem Statement To move the payload using the crane is not an easy task especially when strict specifications on the swing angle and on the transfer time need to be satisfied. Most of the common gantry crane results in a swing motion when trolley is suddenly stopped afier a fast motion. So, to overcome the problem the dynamic feedback swing control is applied to the gantry crane system. The dynamic modeling of gantry crane, designed to transport a small scale models containers using industrially applicable detection and control of dynamic cable swing resulting from very high speed operation, and environmental disturbances such as steady or gusting winds. A state variable feedback controller is designed for the gantry crane position and speed, as well as the load angle and angular velocity in order to move the containers of uncertain mass as quickly, accurately, and safely as possible. 1.4 Scope of Project ’) Literature study on the gantry crane system ii) Study on dynamic feedback swing control to get the better output for gantry crane. iii) Derive the dynamic feedback input function from the specified output function, iv) Implement the input function into the closed-loop system. v) Develop and analyze the dynamic model by using the SIMULINK in the MATLAB software. vi) Design, and built the model gantry crane by using closed-loop systems (involved several types of sensors). Integrate between the hardware and software after all design completed.1.5 Methodology Phasel:- Every week, meet and discuss with supervisor Mrs.Azdiana Binti Md. Yusop and show the project progress. Get more information about the gantry crane from supervisor, internet, books, journal, thesis, and so on. Phase2:- Make a literature review for the project system including study about the ‘component that will be used, their characteristic and understand deeply about the circuit and how it operates and get the datasheet of component involved. Phase3:- For this phase, it called as software development, where involve analyze and study to design a dynamic feedback swing controller. Derive the dynamic feedback input function from the specified output function. Phase4:- For this phase, it called as hardware design. All components must have extra features to make sure the troubleshooting circuit can be done easily. Mechanical drawing for gantry crane also has been done using AutoCAD software. Phase5:- For this final phase, it called performance test. In this phase the software part and hardware part need to be combine together to get the result and to achieve the objective the theoretical. After that, the that already constructed will be tested its functional, ability & weakness. If there is any of project. The final result is then be compared error detected, the troubleshooting process will be done in order to make sure the circuit is well functioning.1.6 Thesis Outlines This thesis consists of five chapters. The following chapters are the outline of the implementation of dynamic feedback swing control of the gantry crane. Chapter I Will di 1uss briefly the overview of this project such as introduction, objectives, methodology and thesis outlines. Chapter II Contains the research and information about the project on several important concepts of dynamic feedback swing control, technology and tools used in the study. Every facts and information, which found through journals or other references, will be compared and the better methods have been chose for the project. This chapter will also include several types of crane. Chapter IIT Includes the detail about designing and modeling the gantry crane system. Simulation results, analysis, observation and discussion of the performance of the dynamic feedback swing control technique are presented in. This chapter all those methodology should be followed to get a better performance. Chapter IV Includes the detail about the hardware design involved schematic diagram, PCB layout, components required and working principle for each circuit. Chapter V Desc is then presented in figures or plotted graph. This chapter also discuss about the 's more about the discussion, and project findings. The result conclusion of the project and the future recommendations,CHAPTER I LITERATURE REVIEW This chapter contains the research and information about the project on several important concepts of dynamic feedback swing control, technology and tools used in the study. Every facts and information, which found through journals or other references, will be compared and the better methods have been chose for the project. This chapter also include several types of crane. 2.1 Definition of Crane A crane is a machine for lifting and lowering a load and moving it horizontally, with the hoisting mechanism an integral part of the machine (refer Figure 2.0). Cranes whether fixed or mobile are driven manually or by power. An automatic crane is a crane which when activated operates through a preset cycle or cycles. A cab-operated crane is a crane controlled by an operator in a cab located on the bridge or trolley.Cranes Hoists used for horizontal movement of materials | used for vertical lifting of materials Hemtwoley Figure 2.0 Differences between Crane and Hoist A semi-gantry crane is a gantry crane with one end of the bridge rigidly supported on one or more legs that run on a fixed rail or runway, the other end of the bridge being supported by a truck running on an elevated rail or runway. Storage bridge ‘crane means a gantry type crane of long span usually used for bulk storage of material the bridge girders or trusses are rigidly or non-rigidly supported on one or more legs. It may have one or more fixed or hinged cantilever ends. Cantilever gantry crane means a gantry or semi-gantry crane in which the bridge girders or trusses extend transversely beyond the crane runway on one or both sides (refer Figure 2.1). Floor-operated crane means a crane which is pendant or nonconduetive rope controlled by an operator on the floor or an independent platform.Hoist wolley Support column Figure 2.1 Bridge Crane Gantry crane means a crane similar to an overhead crane except that the bridge for carrying the trolley or trolleys is rigidly supported on two or more legs running on fixed rails or other runway (refer Figure 2.2). Hot metal handling crane means an overhead crane used for transporting or pouring molten material. Overhead crane means a crane with a movable bridge carrying a movable or fixed hoisting mechanism and traveling on an overhead fixed runway structure. Runway and rails Support column9 Power-operated crane means a crane whose mechanism is driven by electric, air, hydraulic, or internal combustion means. A pulpit-operated crane is a crane operated from a fixed operator station not attached to the crane. A remote-operated crane is a crane controlled by an operator not in a pulpit or in the cab attached to the crane, by any ‘method other than pendant or rope control. Figure 2.3:~ Tower/Jib Crane Figure 2.3 show that the tower or jib crane. A jib crane contai a tilted strut (the jib) that supports a fixed pulley block. Cables are wrapped multiple times round the fixed block and round another block attached to the load. When the free end of the cable is pulled by hand or by a winding machine, the pulley system delivers a force to the load that is equal to the applied force multiplied by the number of lengths of cable passing between the two blocks. T is number is the mechanical advantage.10 2.2 Control System A control system is an arrangement of physical components connected or related in such a manner as to command, direct, or regulate itself or another system. Control system has two important terms, which is define as input and output. The input is the stimulus, excitation or command applied to a control system, Typically from an external energy source, usually in order to produce a specified response from the control system. ‘The output is the actual response obtained from a control system. It may or may not be equal to specified response implied by the input. Figure 2.4 shows a block diagram of a control system. Set-Point —— Controller Actuator Process [—+Controlled ‘Variable (Desired lectronic. ©» Final Control Physical (Measurable Result) _Tnteligent) Element) System) Result) e bLopD Motor, Rotating Heating Element Figure 2.4 A Block Diagram of a Control System 2.2.1 Open-Loop and Closed-Loop Control Systems Control systems are classified into two general categories, open-loop and closed- loop systems. An open-loop system is one which the control action is independent of the output, A closed-loop control system is one in which the control action is somehow dependent on the output.a Open-Loop System is a control system that does not use feedback. The controller sends a measured signal to the actuator, which specifies the desired action, This type of system is not self-correcting. If some external disturbance changes the load on machine or process being performed, some degree of physical effort of human operator is required to make necessary modifications. The system manually controlled by the human, For e.g. the speed of a car controlling by a driver. Figure 2.5 shows an open-loop control system. Set-Point —+] Controller Actuator Process Controlled Variable igure 2.5 Open-Loop Control Systems Closed-Loop System is a control system that uses feedback. A sensor continually monitors the output of the system and sends a signal to the controller, which makes adjustment to keep the output within specification. This automatic closed-loop configuration performs the self-correcting function by employing a feedback loop to keep track of how well the output actuator is doing the job it was commanded to d. A feedback signal is produced by a sensing component that measures the status of the output. ignal is then fed back to the controller. Since the controller knows what the system is actually doing, it can make any adjustments necessary to keep the output where it belongs. Figure 2.6 shows a closed-loop control system. Feedback Figure 2.6 Closed-Loop Control Systems12 2.2.2. Manually & Automatic Control A control system is a device or set of devi ‘es to manage, command, regulate the behavior of other devices or systems. There are two common classes of control systems, with many variations and combinations, logic or sequential controls, and feedback or linear controls. Some devices or systems are inherently not controllable. ‘The term "control system” may be applied to the essentially manual controls that allow an operator to, for example, close and open a hydraulic press, where the logic requires that it cannot be moved unless safety guards are in place. Figure 2.7 shows a manually control for gantry crane. \ON/OFF — yO} [Left “= = Right} ‘Manual Control Figure 2.7 Manually Control for Gantry Crane ‘An automatic sequential control system may trigger a series of mechanical actuators in the correct sequence to perform a task. For example various electric and pneumatic transducers may fold and glue a cardboard box, fill it with product and then seal it in an automatic packaging machine. Figure 2.8 shows an automatic control for gantry crane.2B (Personal Ampliice = Position | Sensor [7 Swing Angie Sensor | ‘Automatic Control| Figure 2.8 Automatic Control for Gantry Crane In the case of linear feedback systems, a control loop, including sensors, contro! algorithms and actuators, is arranged in such a fashion as to try to regulate a variable at a set point or reference value. An example of this may increase the fuel supply to a mace when a measured temperature drops. PID controllers are common and effective in cases such as this. Control systems that include some sensing of the results they are trying to achieve are making use of feedback and so can, to some extent, adapt to varying circumstances. Open-loop control systems do not directly make use of feedback, but run only in pre-arranged ways. 2.2.3 PID Controllers A proportional-integral-derivative controller (PID controller) a generic control loop feedback mechanism widely used in industrial control systems. A PID controller ‘attempts to correct the error between a measured process variable and a desired set-point by calculating and then outputting a corrective action that can adjust the proces: ecordingly.14 The PID controller calculation (algorithm) involves three separate parameters; the Proportional, the Integral and Derivative values. The Proportional value determines the reaction to the current error, the Integral determines the reaction based on the sum of recent errors and the Derivative determines the reaction to the rate at which the error has been changing, The weighted sum of these three actions is used to adjust the process via a control element such as the position of a control valve or the power supply of a heating element, Figure 2.9 shows the PID controllers block diagram. P Vet yt Vout Ove 1 Amp [—| See | Vicedback| D Feedback (Sensor) Figure 2.9 The PID Controllers Block Diagram By “tuning” the three constants in the PID controller algorithm the PID can provide control action designed for specific process requirements. The response of the controller can be described in terms of the responsiveness of the controller to an error, the degree to which the controller overshoots the set-point and the degree of system oscillation, Note that the use of the PID algorithm for control does not guarantee optimal control of the system.15 Some applications may require using only one or two modes to provide the appropriate system control. This is achieved by setting the gain of undesired control outputs to zero. A PID controller will be called a PI, PD, P or I controller in the absence of the respective control actions. PI controllers are particularly common, since derivative action is very sensitive to measurement noise, and the absence of an integral value prevents the system from reaching its target value due to the control action. Table 2.1 show summarizes of the PID terms and their effect on control system. Table 2.2 shows characteristic of P, I, and D (Effects of Increasing Parameters). ‘Table 2.1 Summarizes of the PID Terms and Their Effect on Control System Term Math Function Effect on Control System P Typically the main drive in a control loop, KP | KP x Verror Proportional reduces a large part of the overall error. Reduces the final error in a system. Summing I even a small error over time produces a drive KIx J Verror dt Integral signal large enough to move the system toward a smaller error. Counteracts the KP and KI terms when the D output changes quickly. This helps reduce _ | KDxdVerror/ dt " ees ae P Derivative overshoot and ringing. It has no effect on final error. Table 2.2 Characteristic of P, I, and D (Effects of Increasing Parameters) Parameter Rise Time Overshoot Settling Time S.S. Error Decrease Increase | Smali Change | Decrease Decrease Increase Increase Eliminate | Kd ‘Small Change Decrease Decrease None16 2.2.3.1 Proportional Control The proportional term makes a change to the output that is proportional to the current error value. The proportional response can be adjusted by multiplying the error ven by: by a constant X,, called the proportional gain. The proportional term Pout = Kpe(®) 1) Where, Poy: Proportional output © K,: Proportional Gain, a tuning parameter © e:Error= SP ~ PY ¢ or instantaneous time (the present) A high proportional gain results in a large change in the output for a given change in the error. If the proportional gain is too high, the system can become unstable In contrast, a small gain results in a small output response to a large input error, and a less responsive (or sensitive) controller. If the proportional gain is too low, the control igure 2.10 shows the action may be too small when responding to system disturbances, step response for P controller. 1d Figure 2.10 The Step Response for P Controller7 In the absence of disturbances pure proportional control will not settle at its target value, but will retain a steady state error that is a funetion of the proportional gain and the process gain. Despite the steady-state offset, both tuning theory and industrial practice indicate that it is the proportional term that should contribute the bulk of the output change. 2.2.3.2 Integral Controller ‘The contribution from the integral term is proportional to both the magnitude of the error and the duration of the error. Summing the instantaneous error over time (integrating the error) gives the accumulated offset that should have been corrected previously. The accumulated error is then multiplied by the integral gain and added to the controller output. The magnitude of the contribution of the integral term to the overall control action is determined by the integral gain, Ki. The integral term is given by: Tout = Kifecede (22) a Where, © Joy: Integral output © Ke Integral Gain, a tuning parameter © e: Error =SP~ PV ‘© 1: Time in the past contributing to the integral response18 The integral term (when added to the proportional term) accelerates the movement of the process towards setpoint and eliminates the residual steady-state error that occurs with a proportional only controller. However, since the integral term is responding to accumulated errors from the past, it can cause the present value to overshoot the setpoint value (cross over the setpoint and then create a deviation in the tuning and controller stability, other direction). For further notes regarding integral g: see the section on Loop Tuning. Figure 2.11 shows the step response for P, I, and PI controller. Figure 2.1 1:- The Step Response for P, I and PI Controller 2.2.3.3 Derivative Controller is calculated by determining the slope of The rate of change of the process error the error over time (ie. its first derivative with respect to time) and multiplying this rate of change by the derivative gain Kz. The magnitude of the contribution of the derivative term to the overall control action is determined the derivative gain, Kz. The derivative term is given by:19 Dou = Ka& 23) dt Where, Dow: Derivative output K,. Derivative Gain, a tuning parameter e: Error = SP ~ PY © t: Time or instantaneous time (the present) The derivative term slows the rate of change of the controller output and this effect is most noticeable close to the controller set-point. Hence, derivative control is used to reduce the magnitude of the overshoot produced by the integral component and improve the combined controller-process stability. However, differentiation of a signal amplifies noise in the signal and thus this term in the controller is highly sens noise in the error term, and can cause a process to become unstable if the noise and the derivative gain are sufficiently large. igure 2.12 shows the step response for P, D, and PD controller.20 ‘The output from the three terms, the proportional, the integral and the derivative terms are summed to calculate the output of the PID controller. Figure 2.13 shows the step response for P, PI and PID controller. o 1 2 8 4 5 6 7 8 9 1 Figure 2.13 The Step Response for P, PI and PID Controller2 2.3 Modeling of the Gantry Crane System Figure 2.14 shows the general model of a gantry crane, where is specified by the horizontal position of the trolley, x, the swing angle of the rope, @ and the length of the hoisting rope, L The payload which is suspended from the point suspension, S, is ‘assumed to be a rigid body symmetric about its axis with center point, G, of mass m. Ym Figure 2.14 Model of a Gantry Crane. Some assumptions are made for simplicity before the derivation of the equation of motion. There are friction force in the trolley that may exist is to be ignored, the payload and the trolley can be considered as point masses and the tension force that may cause the hoisting rope elongate is also neglected. The trolley and the payload are ‘assumed to move in two dimensional, which to move x-y plane.2 2.4 Derivation of the Equation of Motion Gantry crane model is the dynamics behaviors [6], so the position vector of point of suspension, $ and the centre point G with respected to the fixed axes coordinates have to be determines. The position vector of S with respected to the fixed axes coordinates system as shown in Figure 2.14 is Fexityy sxi (2.4) Where, iand 7 are x and y directional unit vectors, respectively. ‘The position vector of G with respect to the fixed axes coordinate system is related by the moving circular coordinate, 0, which can be written as: rey @5) Where, x, =x+/sin8 and y, = ‘Therefore, the kinetic energy of the system T can be obtained as: T= Tooley Tplnd =p Mie smn? +3.) 6) =A Mis mi? +9 Where, M and m are the mass of the trolley and the payload, respectively.23 ‘The potential energy of the system, P can be represented as: P=mgyn = -mg/cos 0 Q2 Where, g is the gravitational acceleration or g = 9.81ms”. Using the Lagrangian function, the following equation is derived as: L=T-P aber hinGiy! +hq_°)-+mg/cosd (2.8) From above, it is noticed that xq =x + /cos@ and ym = -/ cos. Hence, the first derivative of Xm and Ym can be obtained as: — dx+/sin8) dt ¥+/sin0 + O(/cos) i+sinO/+/cos08 And _ 40088) dt = -[/cos0 +6(-sin@)] = /sin 06 -icos824 Uherefore, Xn?+¥n2= (%-+sin8/+/cos66) +(/sin66—icosa) 7 + (sin/+/cos00)? +23(sin@/+ /cos0) + /? sin? a6" +P cos? @—2/isin 8 cos06 2ilsin Ocos 00 + +sin’ 07+/° cos* 2:(sin0/+/cos06+/* sin? 66-+/? cos’ 8-2] sin @.cosOO +7? (sin? 0 +cos? 8)+ 6? /°(sin? 6 +cos? 0)+ 2xsin8/+2i/cos60 = P4747 6 42%]sinO +2%/0c080 By substituting Xm” + ym" into equation (2.8), the result for Langrangian function is obtained as: Me dma? 47476? +2¢/sind +2%/6c080+ 2 ‘mg |cos0) 29) ‘After get the Lagrangian function, the equation of motion can be derived. The Lagrange equation is defined as: a(a a 8g ‘Thus, the equation of motion associated with the generalized coordinates (2.10) q=[x,8, /1" are represented. First, the relation of the two a dimensional force is formulated with q = x, whi