An improved input shaping design for an efficient sway control of a nonlinear 3D overhead crane with friction

•We propose an improved input shaping design for control of a 3D overhead crane.•The PSO is used to find optimal parameters for ZV and DZV input shapers.•Simulations show significant reductions in overall and residual payload sways.•Experiments verify the superiority of the improved design in sway reductions. This paper proposes an improved input shaping scheme for an efficient sway control of a nonlinear three dimensional (3D) overhead crane with friction using the particle swarm optimization (PSO) algorithm. Using this approach, a higher payload sway reduction is obtained as the input shaper is designed based on a complete nonlinear model, as compared to the analytical-based input shaping scheme derived using a linear second order model. Zero Vibration (ZV) and Distributed Zero Vibration (DZV) shapers are designed using both analytical and PSO approaches for sway control of rail and trolley movements. To test the effectiveness of the proposed approach, MATLAB simulations and experiments on a laboratory 3D overhead crane are performed under various conditions involving different cable lengths and sway frequencies. Their performances are studied based on a maximum residual of payload sway and Integrated Absolute Error (IAE) values which indicate total payload sway of the crane. With experiments, the superiority of the proposed approach over the analytical-based is shown by 30–50% reductions of the IAE values for rail and trolley movements, for both ZV and DZV shapers. In addition, simulations results show higher sway reductions with the proposed approach. It is revealed that the proposed PSO-based input shaping design provides higher payload sway reductions of a 3D overhead crane with friction as compared to the commonly designed input shapers.