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    Us 20150012188 A 1

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    ‘US 2015001 us United States c2) Patent Application Publica Scheider et al. (3) CRANE CONTROLLER (1) Applicant bherr-Werk Nenzing GmbH Nenzing (AT) (72) Inveotors:. Klaus Schelder, Hergatz (DB); Oliver Sawodny, Ssttgar (DE) UM Schaper, Stuttgart (DE); Bekhard Arnold, lmenan (DE} (21) Appl. Nos 147922,459 (22) Filed: Jul.2,2014 G0) Forcign Application Priority Data Jul. 5,2013 EP) 13003 410.1 Publication Classification GI) Inc Boor 13/18 (2006.01) BOOC 24/82 (2006.01) B66C 13/40 (2005.01), BO6C 24/84 (2006.01) IS8AL iON (10) Pub. No.: US 2015/0012188 Al (43) Pub, Date Jan. 8, 2015 (52) US. coc B66C 13/18 (2013.01); BOO 23784 (2013.01); B66C 2382 (2013.01); BOSC 13740 (2013.01) spc ‘01180;212276 6 ABSTRACT The present invention shows a erane controller forthe semi ‘ulomiatie contol of «rotary erane, the crane comprising at Teast a slewing actuator for creating a slewing motion ofthe ‘and/ora hufing atuatr for ereaing a lufing motion of crane controller comprising an input unit which fed by a operator to provide a desired slewing speed andlor a desired lfling speed as an operator input and 4 model-preditive reference trajectory planning module ‘comprising an optimization unit for calculating a reference trajectory that obeys the system dynamics and follows the ‘operator input, and 2 feedtorward-contoller using the re tence trajectory’ for controlling the slewing atwator andlor the Ioffing actuator. Further, the optimization unit takes into sccount the deflection of the rope in the tangential andior radial direction when solving the optimization problem that provides the reference trajectory Patent Application Publication Jan. 8, 2015 Sheet 1 of 9 ‘US 2015/0012188 AL Fig. 1 Patent Application Publication —_ Jan. 8, 2015 Sheet 2 of 9 ‘US 2015/0012188 AL Fig. 2 Reference Trajectory Planni Joystick w Subject of this paper Patent Application Publication Jan. 8, 2015 Sheet 3 of 9 US 2015/0012188 AI Fig. 3 Top view: 3D view: Patent Application Publication —_ Jan. 8, 2015 Sheet 4 of 9 ‘US 2015/0012188 AL Given initial load velocity er (0 Possible load speed trajectory eLity to=0 nd ‘Time (future) {time of calling the trajectory planner} Patent Application Publication Jan. 8, 2015 Sheet 5 of 9 ‘US 2015/0012188 AL desired trajectory Patent Application Publication —_ Jan. 8, 2015 Sheet 6 of 9 ‘US 2015/0012188 AL Fig. 6 4 Optimization Task ; : wo Lf Optima Control Problem Patent Application Publication —_ Jan. 8, 2015 Sheet 7 of 9 ‘US 2015/0012188 AL m go = > Target velocity w Planned input signal i Slewing rate 0 10 20 30 40 50 60 706 80 90 100 . Time {s] Fg. 7B = APnas La Reflection. sostrint... g 3 0 é 8 7 7 | Pendulum deflection 24722 & 0 10 20 30 40 50 60 70 80 90 100 Time [3] Fig. 7C NBO @ Iteration Counter 9 | Number of IP iterations QO 10 20 30 40 50 60 70 80 90 100 Time (s] Patent Application Publication Jan. 8, 2015 Sheet 8 of 9 ‘US 2015/0012188 AL Fig. 8 optimal control <4 fallback strategy (transit 100% - N 2 2 oo LL ocean eee 3 sown Input signal % (optimal control active) g a Planned load slewing rate 3, | ~100% | «== Input signal @ (fallback planner active) |. . L 0 10 20 30 40 50 60 70 80 90 100 Time [s] Patent Application Publication Jan. 8, 2015 Sheet 9 of 9 US 2015/0012188 AI Fig. 9A 100% 0 | 100 % | Stewing rate | +e» Feedforward input signal @ | —~ Combined input u = & + kT (@-2) i Target velocity w LL 150 165 180 195 210 225 240 Fig OB Time {s] Ymin ~+~ Planned load position gr | > Estimated load position yz | . Position constraints Yypin aNd Ymox 150 165 180 195 210 225 240 Time [s] US 2015/0012188 AI CRANE CONTROLLER BACKGROUND OF THE INVENTION [0001] The present invention relates toa crane controller Torte semi-automatic conteol ofa rotary crane. 10002] Inthe semi-automatic control of. eran, the opera- tor wil provide a desired slewing speed and/or a desired Iuffing speed as an operator input, and a model-predictive reference trajectory planning module ofthe crane controller Will calculate a reference trjectory that obeys the system dynamics and follows the operator input. This reference tr jsctory will be used by a feedforward-controller for eontrok- Ting the slewing actuator and/or the lufing actuator of the 10003] ‘The trajectory planning module will use a physical ‘model ofthe erane anda of the load hanging from the crane, in order to generate a reference trajectory that obeys the system dynamics, Further, the reference tajetory planing module will use an optimization unit for calculating a refer ‘ence trajectory that follows the operator input as quiely as possible. 10004) In prior art rane controllers of this type, the opti ‘mization unit also takes into aecouatthesystem liitations of the crane, in onder to calculate a reference trajectory that the ‘rane actuators can ereate. Further, itis known to use feed forward-controllers having antisway-contrl properties, and which take into aecount the pendulum dynamics ofthe load hanging fom the eranein onder o limit a swaying of the load “during the movement of the crane, Further, some approaches tty tominimize the acceleration ofthe load during ptimina- SUMMARY OF THE INVENTION 10005] The present invention is now directed to improving ‘crane controller or the semi-automatic contro af rotary 10006) For this purpose, the present invention provides @ ‘cane controller for the semi-automatic contol of a rotary ‘rane, the erane comprising atleast a slewing actuator for ‘creating a slewing motion of the erane and a Tufing actuator {or creating luffing motion of theerane. Th crane controller ‘of the present invention comprises an input unit which can be ‘operated by an operator to provide a desired slewing speed andor a desired lffing speed as an operator input, a model- predictive reference trajectory planning module comprising noptimization unit fo calculating a elerence trajectory that ‘obeys the system dynamics and follows the operator inputs, and fesdforward-contoller using the reference trajectory {or controlling the slewing actuator andlor te lffing aetna ‘or. Further, according tothe present invention, the optimiza tion unit takes into account the deflection of the rope ia the tangential andor radial direction when solving the optimiza- tion problem that provides the reference trajectory. 10007] The present invention provides a better anti-sway ‘contol than prior art crane controler, in that the deflection ‘of the rope and thereby the sway of the load is already taken. jntoaeeount during the optimization proces that provides the reference trajectory, Thereby, the reference trajectory plan- ning modile ofthe present invention wil provide a reference trajectory that wll, when used as a basis fora feedforward- ‘controller providea movement ofthe load with imited sway ‘of the load, Jan. 8, 2015 [0008] In. preferred embodiment, the optimization unit of the present invention uses the maximum allowable deflection of the rope as a constraint when calculating the reference teyjectory. Thereby, the optimization unit will make sue that the deflection of the rope will kop within same allowable Timits, Because a deflection ofthe rope wil eae additional strain onthe crane stata, this wil allow to iit such strain to allowable values. Further, this will kop the sway of the rope within certain boundary limits [0009] In further preferred embodiment, the optimization ‘unit of the present invention uses a penalizing funtion for penalizing deflections of the tope and/or changes in the ‘efletion ofthe rope when calculating the reference trajee- tory. Thereby, the optimization process wil refer reference Irajetories that minimize the deflection of the ope andor changes inthe deflection ofthe rope. Thereby the reference {eajectory planning module will provide relerence ajectories that minimize the sway ofthe lad, [010] As stated above, the reference trajectory planning ‘module of the present invention is model-predictve, i. it ‘uses a physical model of the dynamics ofthe erane andlor of the load hanging from the erane. In particular, this physical ‘model may describe the pendulum dynamics ofa load hang- jngon a rape from the tip ofthe boom, and/or the dynamics oF the crane in response to the control of the slewing andor Jnlfing actuator. In particu, the model may describe the slewing angle ofthe boom ofthe erane in dependence on the contro signal ofthe slewing actuator, and/or the lufling angle ‘of the boom of the eran in dependence on the contol signal ofthe lulling actuator, andlor the slewing angle andor rial position of the load dependingon theslewing angle and/or the Juffing angle of the crane and/or the control signal of the actuator [0011] ‘The reference trajectory planning module uses this physical model asa further consti during the optimization process, such thatthe reference trajectory obeys the system ynamics. 0012} Apart from the feedorward controller that uses the reference tnjoctory, the crane controller may furlher come prise, in combination with the feedforward controler, feed- back-controller using one or more sensor signals for feed- back-control of the erane, Using such a feedback-loop will stabilize the control ofthe erane. However, because the re ference trajectory created by the present invention already takes into account the system dynamics, the final contol signal will usually be dominated by the feedforward-control ‘gna, Further, because the deflection ofthe rope is already ‘akon into account during the optimization process that pro- Vides the reference trajectory, its not necessary to inelude anti-sway control in the feedback-controller. However, in a preferred embodiment, als the feedTback-controller includes Antiesway control to reject disturbances, [0013] The feedhack-conteoller may comprise a state ‘observer for estimating the state of the erane system from the signals othe one or moresensors and the contol signals used or eontroling the slewing actuator andor te fuffing acta tor. This estimated state ofthe crane will then he compared ‘with the reference trajectory n order o implement feedback contro [0014] Such a combination ofa feedforward-controer and 4 feedback-controller is preferred. for implementing. the present invention. However the feedforward-contollerof the present invention could also be used without « fecdbock- eontrollee US 2015/0012188 AI [0015] Further prefered features ofthe crane controller of the present invention, and in particular of the optimization unit used for ereating the reference trajectories, will now be ‘describes in the fllowing: 10016) In one embodiment, the optimization unit may use the maximum allowable amplitude and/or the maximom allowable change rate of the control signal forthe slewing ‘actuator andor the lfling actuator asa constraint when solv= Jing the optimization problem tht provides the reference t= §Jectory: This wll make sure that the system limitations, and in Particular the limitations of theactuator and the linitations of the crane structure, are taken into account, 10017] Preferably, ifthe ma signal is ued asa constraint, the optimization unit takes into account possible control input fom te feedback-contoller Otherwise if the reference trajectory is allowed to use the ‘maximunvallowable amplitude ofthe contol signal, a further ‘input from the feedback controller during eontol may drive the actuator ino saturation, Preferably, the contol input rom the fecdback-controller is assumed to he constant over the prediction horizon. In particular, the optimization unit will thereby use a maximum amplitide of the control signal as 2 ‘constrain that is lower than the maximum allowable ampli tude of the contro signal [0018] Ina funher possible embodiment, in normal opers- tion, the optimization unit may use a change rate of the ‘contol signal that ie helow the maximum allowable change Fate of the conteo signal asa constraint. Therefore, in normal ‘operation, the acceleration ofthe actuator will say below the ‘maximum allowable acceleration, thereby keeping the strain ‘onthe erane structure low: [0019] Further, the erine controller preferably comprises ‘an emergency situation detection unit, and the optimization unit uses the maximum allowable change rate of the control sana asa constraint during emergeney operation, This will rake sure that the refereace trajectory that is used for con- twolling the erane during an emergeney situations willuse the ‘maximum acceleration that is available 0020] -Inparicular the emergency situation detetion unit may detect if the input device is revised during a ride, whieh js also called “back-checking”” Ths isthe usual reaction of @ ‘rane operator ithe anticipates acrtieal situation, and there fore sign for an emergency situation 0021} - Theoperation ange of acrane is sometimes limited, Jor example in order to avoid collisions. Further, erane can be used to mave a load from a pre-defined fist position to @ pre-defined second position 10022} | Some prior art approaches have tried to implement such position limitations as position consraitsin theoptimal ‘contol problem. However the inventors ofthe present iwen- tion have realize thatthe optimal trajectories created in this ‘way will not provide the desired trajectory, Le. a trajectory that would reach the desired position as quickly as possible and only break the motion of the crane as late 28 possible 10023] In order to avoid these problems, in possible ‘embosliment ofthe present invention, the operator input will, be aitomatically modified when the crane approaches a posi- tion limit. Thereby; position limits do nothaveto beenteredas ‘constraints inthe optimal control problem, but these limits will enter into the contol problem by modifying the operator input. 10024) _In particular, the operator input may be modified by cut-off function whea the ean sa certin distance from the position limit. Therefore, as longas the erane is outside of Jan. 8, 2015 certain reaion around the position init, the normaloperator input willbe used for the optimization problem. In contrast ‘when the erane enters the predefined region around the pos ‘ion Fit the operator input willbe mei, and in particu Jar wil be set fo zero, Thereby, the crane controller of the present invention Will make sure that the trajectory that is szenerated will stop the crane motion before oF athe position Timi [0023] Preferably. the crane controller comprises stop- ping prediction unit that prdiets @ erane position where the {perio input has to be moxie in order to stop the crane at ‘orbeforethe position limit. Thereby. one doesnot have to use fixed distance from the postion limit, butean use a position ‘atispreicted depending on he circumstances ofthe opera tion of the rane 10026) Ina prefered embodiment, the stopping prediction ‘unit uses a look-up-able providing predefined stopping pre- Géetions depending on the state ofthe erane. Preferably, the Jook-up-tale will provide the stopping prediction depending atleast fom slewing andor lffing speed andor rope deflce- tion angle and/or rope deflection angle speed andor rope Jength andor current contol signal. In particular the look- ‘upsiable will provide the stopping predietion depending on slewing andr luling speed and rope deflection angle [0027] According tothe presentinventon, the optimization ‘uit will solve the optimal control problem over certain predition horizon. This prediction is repeated at short inter al, because the operator input that eaters into the contol problem may change at any time. Ths is referred (0 as @ repetitive optimal control [0028] Preferably. optimization is repeated at lost every 300 ms, further preferably atleast every 200 ms. Fue, the prediction horizon may be atleast 3s, preferably at leas 5s Ina possible embodiment. the prediction horizon may be between 3 sand 30, preferably berween Ss and 205. [0029] _Inorer to solve the optimization problem, the pre= ition horizon is discretized. The numberof the discretiza- tion sepsis directly related tothe caution time that is necessary. Therefore preferably. he numberof discretization steps isbelow 30 in onder to keep the caleulation requirements low. Preferably, at least diseretization stepsare used, turer preferably at leas 5, further preferably ot feast 10. (0030) Ina preferred embodiment ofthe present invention, {te optimal conto! problem is solved in Tess than 130 ms, preferably in less than 100 ms. This will make sure that the Grane reacts quickly 1 the input of the operator, such thatthe ‘underlying optimization process is unnoticeable othe opera tor. However, it one wants 10 make sure that the optimal contro problem is always solved within this time fame, very Jame safety margins have tobe provided. Thereby, the quality ofthe contol is deteriorated, [0031] Therefore, aeconting to « second aspect of the present invention, the present invention provides ane con- teller forthe semi-automatic control of a rotary crane com- prising af least slewing schustor for creating a slewing notion ofthe erane andor Tulfng actuator for creating & {ufling motion of theerane,Theeranecontrollr comprises an ‘nput unit which ean be operated by an operator to provide a desired slewing speed andor a desired tufing speed as an ‘operator input and model-predictve reference trajectory planning module comprising an optimization unit for ealew- lating a reference trajectory that obeys the system dynamics and follows the operator input and feaderwant-contolle sing the reference trajectory for controlling the slewing US 2015/0012188 AI ‘actuator andor the luffing actuator. According tothe Second, spect of the present invention, the crane controller further ‘comprises fallback trajectory planning module, wherein the ‘output ofthe fallback isjecory planning module is used by the feedlorward-controller if the optimization unit of the model predictive reference trajectory planning module does not provide a reference trajectory within a predefined time fame. Thereby, the present invention makes sure that if no solution ofthe optimal control problem is found, or if there fare any other problems in the model predictive reference trajectory planning module, the crane is still under contol 10032] Further, tho erane controller may comprise plausi- bility checking modile for checking whether the trajcctory provided by the model predictive reference trajectory plan- fing modile falls ane or more plassbility entra. In pare ticular, the output ofthe fallback trajectory planning module is used by the feedforward controller if the trajectory pro- vided by the model predictive reference trajectory planning ‘module does nt full the plausibility eriteria checked in the plausibility checking. module, This will make eercin that ‘nly plausible trajectories are used for controling the eran, ‘and if there are filures in the model predictive reference trajectory planning module, the fallback trajectory planning module is used forthe control of the crane. 10033] Preferably, te fallback trajectory planning made ‘reales a rajectory tht brings the crane wa steady state. This ‘wil increase the safety ofthe operation ofthe crane. 10034] Further, the fallback trajectory planning module ‘may comprise a deceleration part designed sueh that it will bring the crane to rest. Preferably, the deceleration part mul- tiplies the curent reference trajectory state witha gain matrix having one eigenvalue at zero and all other eigenvalues being stable 10035] _Proferbly, te fallback trajectory planning module ‘reales a trajectory tha steadily continues he ajectoy fom the model predictive reference trajectory planning modal. Preferably, for this purpose, the fallback trajectory planning ‘module may comprise continsston part making sure that theeranedoes aot abruptly change ts behavior, or that unnee: ‘essary stress is ereted onthe eae strctoe, Preferably. the ‘continvation part takes into account the maximum allowable deceleration, 10036] Preferably, thecrinecontroller according othe se 1d aspect of the present invention has the prefered Features ready deseribed with respect to fstaspectdeseribed above In particular the contoller according tothe second aspect ayy comprise these preferred festures even if it doesnot use the irstaspect, i. does not take into account the deflection oF the rope during the optimization step. 10037] However, in the most preferred embodiment, the first and the second aspect ofthe preset invention are com bined in a single conttolle. 0038] Apart from the crane controllers described above, the present invention further comprises a rotary erane com prising such a erane controller. The crane according to the present invention preferably comprises a slewing tower that ‘can be rotated by the slewing actuator and a boom pivotally ‘mounted to the slewing tower that ean be raised and lowered by the llfing actuator Preferably, thecrane further eomprises a hoisting gear for raising and lowering Toad hanging on a rope. Preferably, the rope is guided over a pulley at the tip of the boom, such thatthe load hanging on the rope wil follow the movement of the tip of the boom with a pendulim dynamic, Jan. 8, 2015 [0039] ‘The crane according to the present invention may be a moveable crane. In particular, the slewing tower may be ‘mounted on an undercarriage, the undercarriage being driv- able by one or more driving axes andlor erawler track, [0040] Te crane controller of the inventive rotary crane preferably as the features ofthe crane controller described above [0041] Further, the resent invention comprises aecomputer program for implementing a erane controller a described Above, In particlag, the computer program may comprise code for implementing aerane controller on crane computer ‘of rotary eran. The computer program of the present nven- ‘ion preferably is stored on a computer-eadable memory. [0042] The present invention further comprises a method Tor the semi-automatic contol of a rotary crane, the crane ‘comprising a least a slewing aetuator for creating a slewing ‘motion of the erane and/or a fffing actuator for ereating a Tuffing motion of the erane, According tothe preset iven- tion, an operator provides a desited slewing speed andlor @ desired lufing speed as an operator input, and a model-pre- tictiverelerence trajectory is planned by solving an optim ‘zatioa problem that peovides a feference trajectory that obeys the system dynamics and follows the operator input. Further, the reference trajectory is used for feedlonwaed contol ofthe slewing actuator andior the luffing actuator. According to a fist aspect othe preset invention, the deflection ofthe rope in the tangential and/or radial direction i taken into acconnt ‘when solving the optimization problem that provides the reference trajectory. According ta second aspect, fallback trajectory is used forthe feedforward control ifthe optimiza. Son pole canot solved within redetemined tine [0043] Preferably, the method ofthe present invention is performed a described above with respect to the inventive ‘rane controller. Preferably, the methox! uses aerane contol- leras described above, BRIEF DESCRIPTION OP THE DRAWINGS. [044] ‘Tae present iavention will now be further described ‘onthe basis ofa specific embodiment, which exemplifies the hove described features with respect to the contro of the sewing motion ofthe rane. [0045] For exemplifying the invention, the following, ig- lures are used showing! [0046] FIG. 1:an embodiment ofa rotary crane seconing to the present invention, [0047] FIG. 2: a schematic diagram of a two-depree of |reedom crane controler according tothe preseat invention, [048] FIG. 3:a top view anda perspective view of rotary rane showing the slewing pestion of the load and of the boom of the rane, [0049] FIG. 4: anexemplary trajectory created according to the present invention, [0050] FIG. S: a diagram showing an optimal tajectory ‘using position constrains and a desired trajectory, [0051] FIG. 6: 2 software block diagram of a trajectory planner including fallback planner according tothe second aspect of the present invention, [0052] FIGS. 7A-C; three diagrams showing the slewing rate, the penduhim deflection of the mpe and the iteration ‘counter for an exemplary sling gear ride where the target velocity is reversed (back-chocking), such that several con- sins become active during deceleration, US 2015/0012188 AI 10053] FIG. 8: diagram showinga simulationof a slewing ear ride with multiple transitions between the optimal cone teol solution and the fallback planner, and 0054) FIGS. 94 and Btw diagrams showing the slewing rate and the load position where position limits are imple- mented by modifying the target velocity according 10 the present invention DESCRIPTION OF THE PREFERRED. EMBODIMENTS, [0085] | Two-deyree-of-feedom control (2DOF), i.e. acom- bination of feedforward and feedback conto, can give good tracking control performance on many’ large-scale robotic systems sue as cranes. Byery 2DOF contro system needs 2 reference trajectory. The generation of this reference tajec- tory is eruial Too slow reference trajectories decrease sys- tem performance, while to aggressive trajectories can easily violate state or inp constraints. This degrades tracking pet= ormance ad can even cause accidents. In case of opertor- ‘controlled rotary cranes he trajectory generation needs to be ‘done in real-ime which limits the number of avilable algo rithms. 0036] For tis purpose, as an embodiment ofthe present Jnention, a realtime repetitive optimal control trajectory planner for rotary eranes i presented. I takes input and state mstrants into aecount. A fallback-stategy is provided in se no optimal contol soktion is found. The embodiment of the present invention is nse for the rwo-dogree of freedom ‘contol of harbor mabile crane. L INTRODUCTION [0087] An embodiment of a erane comprising a control system according to the present invention is shown in FIG. 1 ‘Theerane comprises ower 11 that can be mated around 3 vertical slewing axis by a slewing gear A boom 5 is pivotally ned to the tower 11 such that it ean be raised an lowered around! horizontal lffing axis. As an actuator forthe fling ‘motion, a hydraulic eylinder7is used in the embodiment. A Joad3 is suspended ona ropetbatis guided overa pulley atthe tipof the boom §, The erane comprises a hoisting winch for raising and lowering ofthe load 3 suspended on the rope. [0058] -‘Thecrane control according othe present invention js semi-automati, such that the operator uses joystick 0 set a target velocity © forthe load. A control system needs 10 accelerate (or decelerate) the erane (© this target velocity ‘while compensating pentilim sway Inthe embodiment of the present invention, pwo-degreeof freedom control (2D0F) ‘susedas shown in PIG. 2. Themajor benefit of 2D0F control Js thatthe feedforward performance ean be tuned separately from the feedback loop. To implement 2DOF contre, nomi nal control sighal and a nominal tate trajectory X need to be calculated by a so-called “trajectory planner”. The contol signal u is ulimately built from the nominal control signal ‘and stabilizing feedback, 10059] Under nominal conditions the plant's state x per fecily tacks the planned trajectory &, which means that the sabilizing feedback is zero and the coatro signa Ws dr nated by the nominal contro signal, Trajectory generation is therefore an important task in 2DOF control. [0060] The present embodiment focuses on hav sick ‘nominal trajectories are planned forthe slewing zea ofotary Jan. 8, 2015 crane s shown in FIG. 1, However, the same approach could {equally be used forthe Inling atuater. [0061] ‘The description ofthe embovtiment is organized as follows: In Section Ia slewing gear model is presented and ‘requirements for nominal trajectories are specified. Also, the available computational resources are discussed. In Section IL, an optimal contro! problem: is deduced. This Section includes notes on the implemented solving method a well as ‘fallback strategy in case no optimal control solution can be ‘ound, Finally operational examples forthe congo system of the present invettion ae presented in Section IV Ml PROBLEM SETUP. A. Rotary Crane Model {0062} Inthis section, linear dynamic model forthe slew fg dyna ofthe crane ad the pendulum s ven. The ‘olay position ofthe tower andthe lo is denoted a and th Gee FIG. 3), Their analar velocities ae therefor ad fh, The rope length is denoted as [and the gravitational acceleration is g. The slewing gear velocity follows the entol input ith fintorder hig dysamis. Assuming time constant has oben ® {0063} ‘Theloadatwaysswings around thesspension point ‘with an eigonfegueney of VBE. Thats Lebistte ® (0064) Combining 2) snd ) into a singe state-space rep- resentation wth the sate vector deiniion xz. 8 82] veld [0065] In the remainder ofthis paper the presented ‘dynamic are also used for planning the nominal trajectories and B. Requirements for Rotary Crane Trajectories [0066] In this section, requirements for rotary eran trajec- tories are presented. For traceability reasons, the require ‘meals are umbered [0067] RI The general goal of any trajectory planning lgo~ rithm for semi-automated cranes is 10 calculate @ load Irajectory whose load speed smoothly converges to target velocity as shown in FIG. 4, The target veloity comes from the operator’ joystick, [0068] R2 Since the joystick position can change at any time, the trajectory noeds to be replanned repeatedly fom arbitrary initial conditions. [0069] 3 The planned nominal trajectory needs 10 obey the system dynamics (4), Sinoe the load position in (4) has ardative degree of 4, any load trajectory will bedtime continuously diferentiable. This makes the trajectory smooth in a mathe US 2015/0012188 AI 10070] There are also physical limitations to Joa trajeeto- ries. Prom the erane’s mechanical construction and the hydraulic limits, these ae: 10074] "R4 The amplitude ofthe contrl signal lul needs to ‘he hounded tothe deverain’s maxim speed, 10072] RS Changes of the contro input yield mechanical siress on aetustor components, therefore the ipa rate has to be constrained 10073] "6 The pendulum deflection causes stress on the tower and the boom, 50 has 10 be bounded, 10074] Additionally, there are non-technical requirements [0075] | R7 For safe crane operation itis essential that the system behavior i predictable to the operator, Practical ‘experience shows tht near-seady-state operation is here> {ore advantageous, ie, the pendulum deflection should always be minimized 10076} RS Experience shows thatthe second derivative of the control signal correlates with sirtural vibeations of the crane. Therefore i should be kept small to inerease ‘operor comfort and the aoveptanee othe control system 10077] Finally, there are functional requirements 10078] | R9.A position constraint allows the control system to ensure that state obstacles in the workspace are no hit Altematively such o consiruint can ensure thatthe erane approaches given target postion. Therefore he load pos tion gy ise also needs o be bounded. [0079] R10 When » crane operator anticipates a critical situation, eg collision, natural reactions to reverse the joystick during ride, i, “back-checking”” In sucha sit ation, the planned trajectory news to decelerate as quickly ‘as posible. C. Available Computational Resources 10080] For the trajectory planning algorithm, the available dynamic memory is less restrictive than the computing powwer Since the erane ean only react to changed user input llr the trsjectory planning algorithm finished calculations, the acceptable reaction delay gives an upper bound on the ‘acceplable calculation time. Experience shows that a few 100,000 floating-point operations can be performedina back- around task on target hardware without noticeable delay to the operator. To allow suficient safety margins, the wajeciory planning algorithm should stay well below this number of Aoating-point operations. II TRAJECTORY PLANNING USING REPETITIVE OPTIMAL CONTROL [0081] Trajectory generation offers several degrees of fee- ‘dom which ean be chosen feely within certain constraint. In ‘optimal contr, a trajectory is generated which is optimal ‘with respect to a cost function while fulfilling constraints Many optimal control algorithms need significant computa- Jan. 8, 2015 tion time due to underlying BVP solvers or SQP solves Previous rescarch indicates that tis possible to solve single ‘quadratic program (QP) using interior point algorithms (IP) ‘With te given computational resources of the cranes control ‘nit Therefore the trajectory planning task is formulated as. a Tinite-horizon lineur quadratic discrete-time optimal contol problem (LQDOCP), The inluded crane model ensures that the planned trajectory satisfies the given system dynamics, which makes this a model-predicive trajectory planning Approach, The optimization i repeated every 150/ms with ‘updated initial conditions and an updated joystick position. “This is referred to as repetitive optimal control. A similar approach is taken by. A. Objective Punction and Constraints [0082] Thechosenabjectve function sums up performance Weights, andslock variable weights J, foreach ime step [0083] The performance weights Jy. quadratically penal- ‘es devietions of the planned Toad velocity tothe target velocity w (RI). Since the joystick position cannot be pre- icted, «i assumed constant over the fll predetion horizon ‘The performance weights also penalize pendulums deflee- sions a ‘and changes ofthe pendulum deflection fists (R7) as wel asthe curvature (second derivative) of the nomi sal contol signal (RS) +i Jes = Has, ef, pa [0084] Since the control input curvature Gi in (6) is not ively available as tat variable, itis appeoxinated witha second-order backward diference quotient Ui,» a, {WORS] Thestate variables &,-[b» dnd dave ult thesysem dynamies. Therefore a zero-order hol isretiza- tion of) incl in the opinizaion problem: Be As Bagk (6) witha given initial condition 8 (R2), [0086] Next theinoquality constrains are presented. These ane augmented with sack variables 5.311 #5,320 10 US 2015/0012188 AI void infeasibility problems. The state constraints for the Pendulum deflection (R6) ean be formulated in a straightfor- Ward way: 10087] The nominal control input 0, is bounded by input ‘constraints (R4) and input rate constraints (RS). The input ae ae oy with 0... (K-1). 10088] | Thebounda,,., ischosen with someconservatism to ‘smoothen crane operation. Only in emergency situations, i. when back-checking is detected, ayy, Set its physical ‘maximum (RIO). For the contol iaput constraints, 2 fist ‘approach could be to hound instead of W, 6. Uy 2g ‘This however turns ott to be insufficient: When isa ts ‘maximum, additional stabilizing feedback fom (1) could dive w into actuator saturation. Consequently, the contol ‘input constraints are written as esate ony ay for 0... . (KI), Here, the stabilizing control input k” (,-x(0) is assumed constant over the predietion horizon. 10089] To koop tho slack variables 8, .. 854.28 small as possible, they are penalized inthe cost function: 10090] Weighting slck variables only quadratially yields ‘mall constraint violations whenever constraints become active. This is still acepted since strong linear slack variable ‘weights empirically lead to undesirable increases inthe mum- ber of IP iterations. B, Diseretzation ofthe Phanning Horizon 10091] The optimal contol problem is solved with an iate- Fior point (IP) algorithm which is presented in the following Section II-D. Fach IP tration requiresa small multiple of K (n¢n,?) floating point operations, where n, isthe numberof states anda the amber of iaput variables. Itcan be seen that the computational effort grows linearly with the number of discretization steps K. The choice of K reguines a platform= ‘depeadent ade-off between the calculation time and the prediction accuracy. C- Incorporating Position Constraints 10092] When there is positon bound in the direction of ‘motion, the expected hetavir is tht the erane drives nor ‘mally ss long as possible, Then itis expected to decelerate as Jan. 8, 2015 if the target velocity was zero, resultingin a standstill right on the position bound. The optimal control problem set up in Section I-A does not allow obeying sucl a positon bound (89) so fi, [0093] Its not reasonable to include a postion constraint like }24 inthe optimal conteol problem. Even though the ‘constant would be satisfied, the resulting trajectory would stil be undesirable due to an inconsistency between the cost unetion and the positon constraint. small example helps ‘comprehending the underlying problem: [094] Consider a plant to have simple integrator dynam- jes, ie. isa position and X a velocity. An linea-quadatic ‘optimal control problem with a target velocity of <1, @ prediction horizon of 10 s and a position consrsin of x23 ‘Would look like this: [0095] Both optimat control problems (6) and (15) have ‘quadratic weights of velocity deviations, FIG. 8 shows bath the desired trajectory and the optimal solution ofthe optimal ‘control problem (15), Its infeasible to keep up the target velocity throughout the horizon dueto the position constrain. [0096] The desired trajectory keeps the target velocity of 1 or 3s and rests at the target position afterwards. The optinal solution also coversa total distance of3, but whan averaged velocity of0.3 over the 10s prediction horizon, only eaehing the position bound atthe end of the horizon, The underying reason for this behavior i that uadrati cost functions penal- ine larger deviations of the planned velocity more than smaller ones. One workaround cou be to conte the pre- ction horizon when approaching a target postion. Such an algorithm would! however require solving several QP’ and therefore way more computation time. [0097] Instead of using postion constraints in the optimal ‘control problem, (RO) i filled by modifying the jeystick target velocity © in the objective fanetion (6) with'a cutoft function (0, Xp.) 0098] ‘Tae cutoff function is defined as: fastet [2 0 oer ‘where “stopping prediction” isan accurate prediction ofthe position where the crane comes to rest after transient decel- eration with 9-0. The prediction depends both on the initial US 2015/0012188 AI sate, andthe model parameter, as wellascn the trajectory planner dynamics. No analytic solution for predicting the sopping prediction was found. Therefore the stopping pre- dictions for various combinations of intial states and rope Jengths were calculated fine and stared inalookup table. Ia the control system, the actual stopping prediction is deter ‘mined from this lookup table using Tinea interpolation . Solving the Optimal Control Problem 10099] The presented finite-horizon inear-quadratie dis- ‘retestime optima contro problem consists ofthe cost fune= tion (5) swith (6), (14), (16) and (17, the equality constraints ty constraints (8)(13) Its solved with ype predictorcorrector method. "The ‘most time-consuming step of ths algorithm is the solution oF structured linear system of equations. To explotstructure, a siscrote-time Riceat recursion is used, EB, Fallback Strategy 10100] _1¢3 possible that the optimal contol problem can- not be solved. This might happen dv to namerieal problems, undetected algorithmic Mavs, ori the computation time limit js exceeded (possibly due to higher proctized tasks on the same control nit). Therefore a number of checking algo- rithms monitor the convergence and plausibility ofthe sohi- tion ofthe optimal control problem. In ease of failure, steady ‘continsation ofthe planned state trajectory andthe nominal ‘contol signal is sill required to avoid sudden interruption ‘of erane operation. FIG. 6 shows how this is accomplished: Theplanned state &isintegrated using the dynamic model (4). ‘The nominal inpat is normally taken from the solutionof the ‘ontrol problem, IF this is not available of fails the plausibility checks, a fallback solution Sy is applied instead. This fallback soluion isealculated by acom- binttion of a decelerition part and a continuation function Doon [0101] The gain matrix Ky is designed such that (A¥B Kp) has three asymprotically stable eigenvalues and one ceigeniale at 2-0. This means that the planned state % con- verges 10 some (non-zero) stopping postion while tht the fallback planner is active. The deceleration part ofthe fall back control signal therefore ensures thatthe reference tae Jectony comes to rest. The continuation fanetion Bon) is ‘added to ensure thatthe control signal from the Zallback planner dj, steadily confines the contol signal 0 from the ‘optimal control problem before the wansition. The function Dyn Hinearly reduces from its initial value to zee ion) i guid» Dar ae Feel =V 04g t Bui)

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