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at – Automatisierungstechnik 2021; 69(9): 806–816

Applications

Lukas Ecker*, Tobias Malzer, Arne Wahrburg and Markus Schöberl

Observer design for a single mast stacker crane


Beobachterentwurf für ein Hochregalbediengerät

https://doi.org/10.1515/auto-2021-0018 konstruktion handelt, wird das betrachtete Modell von


Received January 27, 2021; accepted August 9, 2021 gewöhnlichen und partiellen Differentialgleichungen
Abstract: This contribution is concerned with the design beschrieben, d. h. das Modell weist einen gemischt
finite-/infinite-dimensionalen Charakter auf. Im Rahmen
of observers for a single mast stacker crane, which is
dieser Arbeit werden zwei verschiedene Beobachterent-
used, e. g., for storage and removal of loads in automated
würfe vorgestellt, ein Extended Kalman Filter, das auf
warehouses. As the mast of such stacker cranes is typi-
einer finite-dimensionalen Systemapproximation basiert,
cally a lightweight construction, the system under consid-
unter Verwendung der Rayleigh-Ritz-Methode, und ei-
eration is described by ordinary as well as partial differ-
nen Ansatz, der die port-Hamiltonsche Systemdarstellung
ential equations, i. e., the system exhibits a mixed finite-
für das finite-/infinite-dimensionale Szenario ausnutzt,
/infinite-dimensional character. We will present two dif-
wobei insbesondere das Beobachterfehlersystem als port-
ferent observer designs, an Extended Kalman Filter based
Hamiltonsches System formuliert wird. Der finite-/infinite-
on a finite-dimensional system approximation, using the
dimensionale Beobachter sowie das Kalman Filter wer-
Rayleigh-Ritz method and an approach exploiting the port-
den zur Schätzung der Balkenverformung herangezogen,
Hamiltonian system representation for the mixed finite-
wobei lokale Vibrationen durch einen an der Mastsprit-
/infinite-dimensional scenario where in particular the
ze angebrachten Beschleunigungssensor erfasst werden.
observer-error system should be formulated in the port-
Schlussendlich soll anhand von Messungen an einem rea-
Hamiltonian framework. The mixed-dimensional observer
len Labormodell die Leistungsfähigkeit dieser Ansätze in
and the Kalman Filter are employed to estimate the de-
Kombination mit einem Beschleunigungssensor für die
flection of the beam based on signals acquired by an iner-
Überwachung kritischer Größen und die Möglichkeit der
tial measurement unit at the beam tip. Such an approach
Schwingungsunterdrückung demonstriert werden.
considerably simplifies mechatronic integration as it ren-
ders strain-gauges at the base of the mast obsolete. Fi- Schlagwörter: infinit-dimensionale Systeme, energieba-
nally, measurement results demonstrate the capability of sierter Beobachterentwurf, Extended Kalman Filter, Hoch-
these approaches for monitoring and vibration-rejection regalbediengerät
purposes.

Keywords: infinite-dimensional systems, energy-based


observer design, Extended Kalman Filter, single mast 1 Introduction
stacker crane
Single mast stacker cranes (SMCs), also called rack feed-
Zusammenfassung: Dieser Beitrag beschäftigt sich mit ers, are deployed in automated warehouses or logistic cen-
dem Entwurf von Beobachtern für ein Hochregalbe- ters in order to move payloads to desired positions. From
diengerät in automatisierten Lagerhallen. Da es sich an economic point of view, to improve the productivity the
bei dem Mast typischerschweise um eine Leichtbau- intention is to decrease the access time of such stacker
cranes. To this end, stacker cranes are typically build as
*Corresponding author: Lukas Ecker, Johannes Kepler University
Linz, Institute of Automatic Control and Control Systems Technology, lightweight constructions, consisting of driving units in
Altenberger Str. 69, A-4040 Linz, Austria, e-mail: lukas.ecker@jku.at fixed ducts and flexible mast structures. Therefore, a math-
Tobias Malzer, Markus Schöberl, Johannes Kepler University Linz, ematical model of the SMC is characteristically governed
Institute of Automatic Control and Control Systems Technology, by a combination of ordinary differential equations (ODEs)
Altenberger Str. 69, A-4040 Linz, Austria, e-mails:
and partial differential equations (PDEs). However, as a
tobias.malzer_1@jku.at, markus.schoeberl@jku.at
Arne Wahrburg, ABB AG, Forschungszentrum Deutschland, consequence of the lightweight construction undesirable
Wallstadter Str. 59, 68526 Ladenburg, Germany, e-mail: beam vibrations occur. This problem is of increasing rele-
arne.wahrburg@de.abb.com vance in practical applications as stacker cranes in auto-

Open Access. © 2021 Ecker et al., published by De Gruyter. This work is licensed under the Creative Commons Attribution 4.0 International
License.
L. Ecker et al., Observer design for a single mast stacker crane | 807

mated warehouses are ever growing in height due to floor case, in particular the so-called Stokes-Dirac scenario, see,
space constraints. Therefore, the idea is to address the e. g., [11], as well as an approach based on jet-bundle struc-
problem from a control engineering point of view. With tures [13, 14] have turned out to be especially suitable. The
regard to appropriate control methods, for the governing main difference of these approaches is the choice of the
mathematical model it is necessary to distinguish between states – energy variables versus derivative coordinates –
scenarios allowing for an active lifting unit or not. Note see [10] for a detailed comparison by means of the Mindlin
that an active lifting unit implies a more complex model, plate. Furthermore, in [12] the pH system representation
however, it allows to decrease the access time since the based on Stokes-Dirac structures, where strain variables
driving and lifting unit move simultaneously. For exam- are exploited for mechanical systems, has been used for
ple, in [5] a flatness-based feedforward control for the sce- the observer design. The SMC can be modelled in a varia-
nario of an SMC with an inactive lifting unit – i. e., the lift- tional framework, and furthermore, since the beam deflec-
ing unit remains at a constant position – has been pre- tion is of particular interest in our approach, we base our
sented, where the flatness of the mixed-dimensional prob- considerations on the jet-bundle scenario.
lem has been shown. In contrast, in [1] and [3] a flatness- For the purpose of structure health monitoring and
based feedforward control for a finite-dimensional system vibration rejection at least partial information about the
approximation, which was obtained by the Rayleigh-Ritz current distortion of the beam is required. The mentioned
method, has been derived, where an active lifting unit has controllers for the SMC presented in [1, 2] and [3] rely on
been taken into account. Furthermore, in [3] a passivity- the ability to measure the bending moment at the beam
based controller has been proposed for the stabilization of base by the use of a strain gauge. Integrating strain-gauges
the infinite-dimensional error system, whereas in [1, 2] a for directly measuring these quantities of interest can be
dynamic controller based on the so-called energy-Casimir challenging. Therefore, the proposed observer estimates
method has been derived for that purpose. the corresponding signals based on acceleration measure-
In this contribution, instead of discussing a further ments acquired at the tip of the beam.
control methodology for SMCs, we focus on the derivation Thus, the main contributions of this paper are as
of proper observation strategies. A well-known approach follows. In Section 3, we present two observers for the
for linear systems governed by ODEs is the Kalman Fil- model of an SMC with active lifting unit, which is briefly
ter. Moreover, extensions of the Kalman Filter, like the Ex- introduced in Section 2. For the finite-dimensional sys-
tended Kalman Filter (EKF), have become widely used for tem approximation of the SMC, which is obtained by the
the state estimation of nonlinear systems, see, e. g., [4]. Rayleigh-Ritz method, we propose an Extended Kalman
Therefore, the EKF can also be applied for the SMC by con- Filter. Furthermore, based on the pH system represen-
sidering its finite-dimensional approximation. tation we derive a mixed finite-/infinite-dimensional ob-
A further relevant research topic is the observer design server. In Section 4 we provide an experimental validation
for infinite-dimensional systems, see, e. g., [6], where an of both observers on a lab demonstrator, where each ob-
approach based on the so-called backstepping methodol- server is tested in two selected scenarios. In Scenario A
ogy has been presented. Furthermore, in [7] a dissipativity- we confine ourselves to an inactive lifting unit, whereas in
based observer-design strategy has been discussed. How- Scenario B an active lifting unit is considered and further-
ever, note that compared to systems governed by ODEs, in more, also a closed-loop experiment based on a damping
the distributed-parameter scenario there is an enormous injection controller is presented. Section 5 is dedicated to
rise of complexity, as, besides others, the stability analy-
a sketch of the stability proof regarding the asymptotic be-
sis of the infinite-dimensional observer-error systems re-
haviour of the observer-error system of the finite-/infinite-
quires special attention. In fact, functional analytic meth-
dimensional observer where for simplicity we restrict our-
ods are used to show the well-posedness of the governing
selves to Scenario A with an inactive lifting unit at the top.
PDE system, see [8] exemplarily for a detailed closed-loop
stability investigation of a gantry crane with a heavy chain.
To ensure that the observer state indeed converges to the
system state, additionally the asymptotic stability has to 2 Mathematical modelling
be verified, see, e. g., [9], where LaSalle’s invariance prin-
ciple for infinite-dimensional systems was used. In this section we briefly recapitulate the derivation of
In this contribution, we exploit a certain port- the mixed finite-/infinite-dimensional model based on the
Hamiltonian (pH) system representation for the observer variational principle together with its port-Hamiltonian
design. It should be noted that for the infinite-dimensional representation, as well as a finite-dimensional system
808 | L. Ecker et al., Observer design for a single mast stacker crane

approximation obtained by means of the Rayleigh-Ritz


method, see [1, 3] and [15] for more details. The considered
physical model, see Fig. 1, consists of three main mechan-
ical parts. The position of the rigid driving unit with mass
mw is denoted by x1 . The mast with the constant length L,
the mass density ρA and the flexural rigidity EI is clamped
onto the driving unit and meets the Euler-Bernoulli hy-
pothesis. A lifting unit with the mass mh , described by its
vertical and horizontal position x2 and x3 , respectively, is
attached to the mast. Furthermore, the absolute position
of the mast is denoted by w, and its spatial derivatives are
represented with the subscript Y, where wYY denotes the
second spatial derivative of the deflection for instance. The
horizontal position of the tip mass mk at the beam end is
specified by the coordinate x4 . The rotational moments of
inertia of the beam, the tip mass and the lifting unit are not
Figure 1: Schematic of the Single Mast Stacker Crane.
taken into account. Moreover, the electrical dynamics are
assumed to be much faster than the mechanical ones and
are therefore neglected. Hence, the forces F1 and F2 , which
are enforced by a subordinated control loop, serve directly the lifting-unit position for instance. Furthermore, follow-
as manipulated variables of the actuated driving and lift- ing the so-called extended Hamilton principle, i. e., solv-
ing unit, and are considered as control inputs. It should ing the variational problem δL = 0, one can obtain the
be noted that we use tensor notation, i. e., upper (lower) equations of motion, which consists of the partial differ-
indices represent components of contravariant (covariant) ential equation for the Euler-Bernoulli beam
vectors, with powers of variables enclosed in parentheses,
e. g., (x1 )2 . ρAẅ + EIwYYYY = 0, (3a)

the ordinary differential equations of the driving unit, the


2.1 Finite-/infinite-dimensional model lifting unit and the tip mass

Under the assumptions mentioned above the overall ki- mw ẍ 1 + EI wYYY |0 = F1 (3b)
netic energy of the single mast stacker crane reads as 2 3
mh ẍ + mh g + mh ẍ wY |x2 = F2 (3c)
1 1 EI ( wYYY |x−2 − wYYY |x+2 ) = mh ẍ 3 (3d)
Ekin = mw (ẋ 1 )2 + mh ((ẋ 3 )2 + (ẋ 2 )2 )
2 2 4
L EI wYYY |L = mk ẍ , (3e)
1 1
+ mk (ẋ 4 )2 + ∫(w)̇ 2 ρAdY (1)
2 2 and are restricted to the kinematic boundary conditions
0
and mechanical constraints
while the overall potential energy is given by
L w|0 = x 1 wY |0 = 0 (4a)
1
Epot = mh gx2 + ∫ EI(wYY )2 dY. (2) w|x2 = x 3
w|L = x 4
(4b)
2
0
wYY |x−2 − wYY |x+2 = 0 wYY |L = 0. (4c)
Therefore, the Lagrangian is considered to be of the form
L = Ekin − Epot + Eext = L(x, ̄ x)̇ + ∫L l(w,̇ wYY )dY with the Here, the quantities x+2 and x−2 denote the upper and the
0
internal energies (1), (2) and external contributions Eext = lower limit of the lifting-unit position x 2 . The equations of
x1 F1 + x2 F2 . Moreover, the Lagrangian functional is result- motion (3) and (4) correspond to a mixed finite-/infinite-
t
ing in L = ∫t 2 L + λi (t)Θi dt where the quantities λi cor- dimensional problem, where the Euler-Bernoulli beam
1
respond to the Lagrange multipliers with their associated equation (3a) is valid on the spatial domains D1 = [0, x−2 ]
mechanical constraints Θ1 = x3 − w|x2 and Θ2 = x 4 − w|L . and D2 = [x+2 , L]. Obviously, w|x−2 = w|x+2 and wY |x−2 = wY |x+2
Note that we use Einstein’s summation convention to im- apply at the interface of the domains D1 and D2 . Addition-
prove readability and w|x2 denotes the beam deflection at ally, note that the conditions (4c) are a consequence of the
L. Ecker et al., Observer design for a single mast stacker crane | 809

fact that we neglected the rotational inertia of the tip mass, Here, the canonical skew-symmetric matrix Jf and the in-
the beam and the lifting unit. Moreover, for practical ap- ternal input matrix GQ , which reads as
plications, i. e., health monitoring, fault detection or ad-
vanced control purposes, several physical quantities such 0 0 0 1 0 0 0
[ ]
as the bending moment and the shear force are of great [0 0 0 0 1 0 0]
[ ]
interest. It should be noted that in equation (3) and (4) [0 0 0 0 0 1 0]
[ ]
[0 0 0 0 0 0 1]
the second and third spatial derivatives correspond to the [ ]
Jf = [ ],
bending moment M and the shear force Q evaluated at spe- [−1 0 0 0 0 0 0]
[ ]
[0 0 0 0 0 0]
cific spatial positions Y = h, i. e., [ −1 ]
[0 0 −1 0 0 0 0]
[ ]
M|h = EIwYY |h , Q|h = −EIwYYY |h . (5) [0 0 0 −1 0 0 0]

0 0 0
[ ]
[0 0 0]
[ ]
2.2 Port-Hamiltonian representation [0
[ 0 0]]
[0 0 0]
[ ]
GQ = [
In this section the finite-/infinite-dimensional problem, [0 0 1]
]
[ ]
given in Section 2.1, is represented as a port-Hamiltonian [0
[ −wY |x2 0]]
system. For this purpose, we introduce by means of regular [0
[ 1 0]]
Legendre mappings the momenta p1 = mw ẋ 1 , p2 = mh ẋ 2 , [1 0 0]
p3 = mh ẋ 3 , p4 = mk ẋ 4 and pb = ρAw.̇ Subsequently, the
Hamiltonian of the SMC can be written as describe the internal power flow of the finite-dimensional
part and allows to incorporate the constraint forces
1 (p1 )2 1 (p2 )2 + (p3 )2 1 (p4 )2 Q = [Q|L , Q|x2 , Q|0 ]T = [EIwYYY |L , EI(wYYY |x−2 − wYYY |x+2 ),
H = + +
2 mw 2 mh 2 mk
⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟ −EIwYYY |0 ]T , respectively. Furthermore, the internal power
Hf
flow of the infinite-dimensional part is represented by the
L
1 1 1 canonical skew-symmetric operator Ji and the external in-
+∫ (pb )2 + EI(wYY )2 dY. (6)
2 ρA 2
⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟ puts F = [F1 , F2 ]T can be included by means of the input
0
Hi mapping GF .

The partial derivative of the finite-dimensional part T


0 1 0 0 0 0 1 0 0 0
with the Hamiltonian Hf and state xf = [x 1 , x2 , x 3 , x 4 , Ji = [ ] , GF = [ ]
p p −1 0 0 0 0 0 0 1 0 0
p1 , p2 , p3 , p4 ]T yields 𝜕xf Hf = [0, mh g, 0, 0, mp1 , mp2 , m3 , m4 ]T ,
w h h k
where 𝜕xf = 𝜕/𝜕xf . Contrary, the infinite-dimensional part
Consequently, the output of the port-Hamiltonian system
in the port-Hamiltonian representation can be stated with
(7) collocated to the external input F1 and F2 reads as
xi = [w, pb ]T , where its corresponding variational deriva-
p
tive reads δxi Hi = [δw Hi , δpb Hi ]T = [EIwYYYY , ρAb ]T as
y 𝜕 H p (m )−1
ye = [ e,1 ] = GFT δH = [ p1 f ] = [ 1 w −1 ] , (8)
ye,2 𝜕p2 Hf p2 (mh )
δw Hi = 𝜕w Hi − dY (𝜕wY Hi ) + dY (dY (𝜕wYY Hi ))
whereas those of the constraint forces are given by y𝜕,1 =
p
and δpb Hi = 𝜕pb Hi with the total derivative 𝜕p1 Hf = mp1 , y𝜕,2 = 𝜕p2 Hf = mp2 , y𝜕,3 = 𝜕p3 Hf = m3 and y𝜕,4 =
w h h
p
𝜕p4 Hf = m4 . Moreover, by means of integration by parts it
dY = 𝜕Y + wY 𝜕w + wYY 𝜕wY + wYYY 𝜕wYY + wYYYY 𝜕wYYY
k
can be shown that the Hamiltonian functional (6) evolves
along solutions of (7) according to H ̇ = mp1 F1 + mp2 F2 , see
with 𝜕wYY = 𝜕/𝜕wYY . Therefore, the mixed-dimensional
w h
[15] for a detailed computation.
model represented as pH system can be written as
Remark 1. Note that due to the expression −wY |x2 in the ma-
ẋ J 0 𝜕xf Hf G G trix GQ it becomes obvious that the system possesses a non-
[ f] = [ f ][ ] + [ F ] F + [ Q ] Q. (7) linear characteristic regarding the coupling expression in
x ̇
⏟⏟⏟⏟⏟⏟⏟i 0 J δxi Hi
i ⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟
⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟ 0
⏟⏟⏟⏟⏟⏟⏟⏟⏟ 0
⏟⏟⏟⏟⏟⏟⏟⏟⏟
x J δH GF GQ the principle of the conversation of momentum (3c).
810 | L. Ecker et al., Observer design for a single mast stacker crane

2.3 Finite-dimensional approximation At this point, only the determination of the ansatz function
Φ1 (Y) is remaining. As mentioned before, a proper ansatz
A finite-dimensional model can be obtained by approxi- for the deflection must satisfy the equation of the Euler-
mating the deformation of the beam w(Y, t) by appropri- Bernoulli beam, as well as the kinematic boundary con-
ate ansatz functions. In fact, the beam deflection w(Y, t) is ditions and, as far as possible, also the dynamical restric-
approximated by the first-order Rayleigh-Ritz ansatz tions. Therefore, our intention is to construct solutions for
the partial differential equation of the beam via separation
w∗ (Y, t) = x1 (t) + Φ1 (Y)q̄ 1 (t) (9)
of variables. In this way, the resulting eigenfunctions of the
with a spatial ansatz function Φ1 (Y) and the generalised infinite-dimensional problem might be chosen as ansatz
coordinate q̄ 1 as a solution of the Euler-Bernoulli equation functions. An additional challenge arises from the fact that
(3a) fulfilling the kinematic boundary conditions and dy- the eigenfunction problem in the general case depends on
namical restrictions at the beam tip. By substituting the the lifting position x 2 . This in turn means that we have to
ansatz (9) into the energies (1), (2), and using Einstein’s solve nonlinear equations depending on the state of the
sums convention, one can obtain the Lagrangian as lifting unit in order to determine the eigenfunction, which
implies significant computing efforts. Therefore, we use as
L ansatz function the first eigenmode of the Euler-Bernoulli
L(q, q)̇ = L(q,
̄ q)̇ + ∫ l(ẇ ∗ , w∗ )dY
YY (10a) beam, where the lifting unit is neglected, which results in a
0 problem that is independent of x 2 . This simplification was
1 justified by numerical investigations, see [15]. Considering
= Mαβ (q)q̇ α q̇ β − V(q) (10b)
2 the spatial domain D = [0, L], the fundamental solution
with α, β = 1, . . . , 3, the generalized coordinates q = has the form
[x 1 , q̄ 1 , x2 ] and the symmetric mass matrix M = [Mαβ ].
Φ1 = A sin(γY) + B cos(γY) + C sinh(γY) + D cosh(γY) (14)
As a result, the Euler-Lagrange equations of the model of
the finite-dimensional approximation of the single mast ρA
with γ 2 = ω√ EI . The remaining task is the determination
stacker crane can be written as
of the coefficients [K j ] = [A, B, C, D] as well as the eigenfre-
Mαβ (q)q̈ β + Cα (q, q)̇ = Qα (11) quency ω. This can be achieved by substituting the ansatz
(14) in the adapted boundary constraints (3e) and (4) to ob-
where the mass matrix, with the ansatz abbreviation Φ̃ 1 = tain a system of equations Gkj (ω)K j = 0, k = 1, . . . , 4. By nu-
Φ1 (x2 ) and its spatial derivations, is represented by merically solving the nonlinear equation det(G(ω)) = 0 for
the first eigenfrequency ω, we obtain a non trivial solution
m11 m12 + mh Φ̃ 1 mh 𝜕Y Φ̃ 1 q̄ 1 for K and therefore a proper ansatz function Φ1 (Y).
m22 + mh Φ̃ 21 mh Φ̃ 1 𝜕Y Φ̃ 1 q̄ 1 ]
[ ]
M=[ ⋅ (12)
1 2
[sym. ⋅ mh + mh (𝜕Y Φ̃ 1 q̄ ) ]

with the constant mass abbreviations m11 = ρAL + mh +


L
3 Observer design
mk + mw , m12 = ρA ∫0 Φ1 (Y)dY + mk Φ1 (L) and m22 =
L
ρA ∫0 (Φ1 (Y))2 dY + mk (Φ1 (L))2 . In this approximation, the The focus in this section is on the design of two observers
vector C = [Cα ] and the input matrix G = [Gαξ ], where for the SMC. To begin with, we briefly present an Ex-
tended Kalman Filter for the finite-dimensional approx-
Qα = Gαξ uξ , are given by
imated model. Afterwards, in Section 3.2 a pH observer
mh (ẋ 2 )2 𝜕YY Φ̃ 1 q̄ 1 + 2mh ẋ 2 𝜕Y Φ̃ 1 q̇̄ 1 1 0 based on the mixed finite-/infinite-dimensional character-
[ L
C = [ EIq1 ∫ (𝜕YY Φ1 )2 dY + Φ̃ 1 C1 ] , G = [0
] [ ]
0] . istics of the SMC is presented.
0
[ C1 𝜕Y Φ̃ 1 q̇̄ 1 + mh g ] [0 1]

Therefore, with M̄ denoting the inverse of the mass matrix 3.1 Extended Kalman Filter
(12), the state-space system representation of the approxi-
This section is dedicated to the observer design based on
mated model can be written as
the finite-dimensional system approximation (11). As men-
q̇ α vα tioned, the aim is to design an algorithm in order to esti-
[ α ] = [ ̄ αβ ]. (13) mate the shear force and the bending moment at the bot-

⏟⏟⏟⏟⏟⏟⏟⏟⏟ −M (q)Cβ (q, v) + M̄ αβ (q)Gβξ uξ
⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟⏟
ẋ α f α (x) tom of the flexible beam, respectively, which are of particu-
L. Ecker et al., Observer design for a single mast stacker crane | 811

lar importance with regard to vibration suppression. If the measurement noise, i. e., wk ∼ (0, Qk ) and vk ∼ (0, Rk ), the
ansatz function is used for the deflections in (5), the prob- prediction step reads as
lem corresponds to estimate the Ritz variable q̄ 1 , see
Pk+1

= Fk Pk+ FkT + Lk Qk LTk (18a)
1 1
M|0 = EI𝜕YY Φ1 (0)q̄ , Q|0 = −EI𝜕YYY Φ1 (0)q̄ . (15) x̂k+1

= fk (x̂k , uk , 0) (18b)

With the objective to do state estimation without measur- where the measurement update can be written as, see [4],
ing the bending moment by the use of a strain gauge, our
effort is to develop an observation strategy with the ac- Kk = Pk− HkT (Hk Pk− HkT + Mk Rk MkT )−1 (19a)
celeration a|L of the beam tip as alternative measurement x̂k+ = x̂k− + Kk (yk − hk (x̂k− , 0)) (19b)
unit. Therefore, the idea is to abstract the velocity q̇̄ 1 by Pk+ = Pk− − Kk Hk Pk− . (19c)
the given measurements including the acceleration and
utilize it as input for the observer. This issue will be ex-
plained in detail in Section 4. For a finite-dimensional ob- 3.2 Infinite-dimensional observer
server design, we rely on a nonlinear version of the well-
The underlying idea is to exploit the port-Hamiltonian sys-
known Kalman Filter, namely the Extended Kalman Filter.
tem representation and its collocated outputs for the ob-
Originally developed for linear systems, the Kalman Filter
server design, by using a copy of the plant extended by an
assumes that the probability density function of the state
observer-correction term K,̂ where it is assumed that the
and the noises are Gaussian distributed. The crucial ad-
driving unit position x1 , the lifting unit position x 2 and the
vantage in this assumption consists in the fact that the lin- p
velocity of the beam tip w|̇ L = m4 are available as measure-
ear equations obtain the Gaussian distribution of the state, k
ment quantities. If the system were linear, the observer-
which can be fully described by its two first stochastic mo-
error system could be formulated in the pH framework in a
ments, namely the expectation x̂ and the variance P, x ∼
straightforward manner, however as stated in Remark 1 the
(x,̂ P). Therefore, instead of transforming the whole prob-
overall model exhibits a nonlinear characteristics. By ex-
ability density function from one time step to the next and
ploiting the fact that x 2 is available as measurement quan-
inferring measurements, the Kalman filter restricts the pre- tity, we immediately obtain a linear system with the re-
diction and measurement update to the first two stochastic duced observer state x̂ = [x̂ 1 , x̂ 3 , x̂ 4 , p̂ 1 , p̂ 3 , p̂ 4 , w,̂ p̂ b ]T .
moments. For this purpose we consider a discretization of
the system (13) as Remark 2. It should be stressed, that due to the measure-
ment x 2 we omit the corresponding balance of linear mo-
xk+1 = fk (xk , uk , wk ) (16a) mentum (3c). However, as (3d) remains, the coupling of the
active lifting unit and the beam is still valid.
yk = hk (xk , vk ) (16b)
The observer-correction terms K̂ = [k̂ 1 , k̂ 2 ]T are intro-
with the time index k, the system state xk = [xk1 , q̄ k1 , xk2 , duced such that on the one hand, k̂ 2 is collocated to the
ẋk1 , q̇̄ k1 , ẋk2 ]T ∈ ℝ6 , the output quantities yk = [xk1 , q̇̄ k1 , xk2 ]T ∈ velocity of the beam tip in order to impose a dissipative
ℝ3 , the input uk = [F1 , F2 ]T ∈ ℝ2 as well as the process and behaviour on the observer error, and on the other hand,
measurement noise wk ∈ ℝ6 and vk ∈ ℝ3 , respectively. In k̂ 1 can be used to overcome steady-state errors of the driv-
the following, we denote an estimation of the state with ing unit position. As a result of the chosen structure of the
x̂k and the a posteriori and a priori estimation with x̂k+ and observer, which reads as
x̂k− . These terms are of particular importance, because the
ẋ̂ J 0 𝜕 ̂ Ĥ G G G
Taylor series expansions of the equations (16) along these [ ḟ ] = [ f ] [ xf f ] + [ F ] F1 + [ Q ] Q̂ + [ K ] K̂
x̂i 0 Ji δx̂i Ĥ i 0 0 0
states corresponds to the linearised system
with
xk+1 = Fk xk + Lk wk + ũ k (17a)
yk = Hk xk + Mk vk (17b) 0 0 0 1 0 0 0 0 0
[ ] [ ]
[0 0 0 0 1 0] [0 0 0]
[ ] [ ]
𝜕f 󵄨 𝜕f 󵄨 [0 0 0 0 0 1]] [0 0 0]
with the Jacobi matrices Fk = 𝜕xk 󵄨󵄨󵄨󵄨x̂+ , Lk = 𝜕wk 󵄨󵄨󵄨󵄨x̂+ , Hk = Jf = [ G Q = [ ],
k k [−1
[ 0 0 0 0 0]] [0
[ 0 1]]
𝜕hk 󵄨󵄨 󵄨
󵄨 , Mk = 𝜕h
𝜕x 󵄨󵄨x̂k−
k 󵄨󵄨
𝜕v 󵄨󵄨x̂k−
and the input ũ k = fk (x̂k+ , uk , 0) − Fk x̂k+ . [
[0 −1 0 0 0 0]
] [
[0 1 0]
]
Under the assumption of mean-free Gaussian process and [0 0 −1 0 0 0] [1 0 0]
812 | L. Ecker et al., Observer design for a single mast stacker crane

Table 1: SMC laboratory model and observer parameter.

Symbol Value Symbol Value Symbol Value Symbol Value


mw 13.1 kg L 0.53 m mk 0.32 kg α 3000
mh 0.86 kg EI 14.97 N m2 ρA 2.1 kg/m β 20

the constraint shear forces Q̂ = [Q|̂ L , Q|̂ x2 , Q|̂ 0 ]T = If we investigate the formal change of the Lyapunov
[EI ŵ YYY |L , EI(ŵ YYY |x2 − ŵ YYY |x2 ), −EI ŵ YYY |0 ]T , the input
− +
functional (22), which corresponds to the collocated en-
matrix GF = [0, 0, 0, 1, 0, 0]T and ergy ports and the derivation of the incorporated term

of Remark 3, Hė̃ = − mp1 k̂ 1 − m4 k̂ 2 + α mp1 w|̃ 0 , we find
̃ ̃
w k w
0 1 0 0 0 1 0 0 p̃
that the choice k̂ 1 = αw|̃ and k̂ 2 = β 4 = βw|̇̃ with
Ji = [ ] , GKT = [ ], 0 mk L
−1 0 0 0 0 0 0 1 0 < β ∈ ℝ, renders the evolution of (22) along solu-
p̃ 2
tions of the error system (20) to Hė̃ = −β ( 4 ) ≤ 0, andmk
the error system with state x̃ = [x̃ 1 , x̃ 3 , x̃ 4 , p̃ 1 , p̃ 3 , p̃ 4 , w,̃ p̃ b ], therefore the energy functional (22) does not increase. It
i. e., x̃ = [x 1 − x̂ 1 , x3 − x̂ 3 , x4 − x̂ 4 , p1 − p̂ 1 , p3 − p̂ 3 , p4 − p̂ 4 , w − should be stressed, that this finding does not yet imply
w,̂ pb − p̂ b ], can be deduced as that the observer-error system is asymptotically stable. In-
stead, the well-posedness and the asymptotic stability in
ẋ̃ J 0 𝜕x̃f H̃ f G G the light of LaSalle’s invariance principle has to be inves-
[ ḟ ] = [ f ][ ] + [ Q ] Q̃ − [ K ] K̂ (20)
x̃i 0 Ji δx̃i H̃ i 0 0 tigated. However, we want to emphasize that this proof of
the asymptotic stability is not trivial, since for LaSalle’s in-
where the outputs (21) are collocated to the observer- variance principle the solution of two mixed-dimensional
correction terms k̂ 1 and k̂ 2 systems with time variant domains [0, x−2 (t)] and [x+2 (t), L]
must be determined. We therefore confine ourselves with
ỹ 1 𝜕x̃f H̃ f −w|̇̃
[ k2̂ ] = − [GKT 0] [ ] = [ ̇ 0] . (21) the non-increasing energy functional and show the appli-
ỹ ̂ δx̃i Hi ̃ −w|̃ L
k cability of the observer by means of experiments on the
laboratory model and present a more detailed stability in-
Subsequently, we show that by a proper choice of K,̂ it vestigation only for a special scenario in Section 5.
suffices to use the beam tip velocity w|̇ L and the driving-
unit position x1 = w|0 regarding the error-injection
terms for the observer. For the design of the observer
we utilize a Lyapunov functional that consists of the er- 4 Experimental results
ror Hamiltonian H ̃ = 21 m1 (p̃ 1 )2 + 21 m1 (p̃ 3 )2 + 21 m1 (p̃ 4 )2 +
L
w h k
In the following, the application of both observers are val-
∫0 21 ρA
1
(p̃ b )2 + 21 EI(w̃ YY )2 dY extended by a term depending idated by measurement results obtained from a labora-
on the error of the deflection at the bottom of the mast, tory model of a single mast stacker crane, where the pa-
i. e., we have rameters are stated in Table 1. It should be mentioned
α that several control strategies for equilibrium point sta-
Hẽ = H ̃ + (w|̃ 0 )2 . (22) bilization as well as for trajectory tracking purposes have
2
been successfully implemented for the finite and mixed-
Remark 3. Note that the necessity of the additional term in dimensional problem, see, e. g., [1] and [3]. Exemplarily,
(22) turns out within detailed well-posedness investigations. an IDA-PBC law from [3] is given by
If we omit this term, we are not able to detect steady state
1 − α1
errors since we have no information about the error deflec- F1,e = −c1 xe1 − α2 ẋe1 − Qe (23a)
α1
tion. Furthermore, the equivalence of the energy norm ||χ||X ,
F2,e = −c2 xe2 − α1 α3 ẋe2 (23b)
where Hẽ = 21 ||χ||2X can be used as a Lyapunov functional
with regard to stability investigations, and the natural norm with the error terms xe1 = x 1 −xd1 , xe2 = x2 −xd2 and Qe = Q−Qd ,
||χ||n of an appropriate function space X , where χ ∈ X , can- where the index d represents reference trajectories, and
not be shown. This fact implies that the observer-error sys- ci (ξ )ξ > 0 for ξ ≠ 0, i = 1, 2 and ci (0) = 0 as well as
tem would not be well-posed. To overcome this, we incorpo- α1 , α2 α3 > 0 are degrees of freedom. Therefore, the knowl-
rate the term α2 (w|̃ 0 )2 . edge of the shear force and the bending moment is not
L. Ecker et al., Observer design for a single mast stacker crane | 813

only beneficial for structural health monitoring applica-


tions, but also for advanced control strategies, such as,
e. g., vibration rejection, see (23), where the shear force
Q = EIwYYY |0 is required. As mentioned in Section 3.1, the
finite-dimensional scenario give us a direct proportional
relation between the Ritz coordinate q̄ 1 and the bending
moment, which is measurable by a strain gauge, as well as
the shear force Q, see (15). Moreover, the Ritz coordinate
is also associated with the relative deflection wrel (Y, t) =
w(Y, t)−x1 (t) = Φ1 (Y)q̄ 1 (t), see (9), which furthermore give
us a relation between the deflection of the beam at a spe-
cific position Y and the shear force. The laboratory model
possesses a strain gauge in order to measure the bending
moment and the shear force, respectively, although, it is Figure 2: Scenario A: Comparison of the EKF and the pH observer in
not a favoured and common tool. Instead, IMUs for mea- a open-loop scenario with inactive lifting unit at the beam tip.
suring the acceleration at the tip of the beam may be a vi-
able alternative for high bay racks with unguided masts.
Therefore, an obvious intention is to apply acceleration
parison between the two proposed observers and measure-
measurements for the abstraction of the shear force and
ments by means of the driving unit position and the beam
the bending moment. It is well known that double integra-
tip deflection, where the subscripts EKF and pH indicate
tion of noisy acceleration signals is not advisable. It should
the observer quantities of the Extended Kalman Filter and
be mentioned that there exists methods, such as comple-
the port-Hamiltonian observer, respectively. Note that the
mentary filters, see, e. g., [19], to determine the position
bending moment measured by the strain gauge serves as
from acceleration measurements. However, for the sensor
reference measurement for the beam deflection, where the
configuration of the laboratory model under consideration
relation between the bending moment and beam deflec-
it turned out that this approach is not suitable.
tion stems from the Ritz ansatz function as explained at the
In fact, our intention is to exploit filtered measure-
beginning of this section. Furthermore, it should be noted
ments of the beam tip acceleration a|L of the laboratory
that the (not very sophisticated) chosen trajectory plan-
model as well as the positions x1 , x2 of the driving unit
ning was used on purpose, although we are aware of the
and lifting unit as input signals for the Extended Kalman
fact that there exists proper methods like flatness based
Filter and the energy-based infinite-dimensional observer,
trajectory planning, see [3, 5, 1]. However, our main inten-
where the velocity of the beam tip is obtained according to
tion is to verify the capability of the observers and there-
the discrete transfer function
fore we chose trajectories such that the eigenfrequencies
1 − e(−wo Ta ) Ta of the model are stimulated.
ẇ rel |L (z) = T
a|L (z) − ẋ 1 (z)
z−e (−w o a ) z − e(−wu Ta )
Scenario B (active lifting unit): In the second experi-
with the cutoff frequencies wo = 200 s−1 and wu = ment, we demonstrate the capability of both observers for
1 s−1 . Furthermore, it should be noted that with respect to an active lifting unit, where the driving unit as well as the
the infinite-dimensional observer the shear force and the lifting unit were driven simultaneously from x 1 = 0.1 m and
bending moment can be approximately obtained by the x 2 = 0.1 m to x 1 = 0.3 m and x 2 = 0.15 m using the same PD
use of the Finite-Difference method for (5). For compari- trajectory planning as in Scenario A. Furthermore, in or-
son and validation of the two introduced observers from der to show the applicability of the proposed observers for
Section 3 we present the results from two experiments. vibration rejection purposes, the control law (23) is acti-
Scenario A (inactive lifting unit): In the first experiment, vated at the time t = 5 s where the shear force stems from
we propose a scenario of an SMC with inactive lifting unit the Extended Kalman Filter and the infinite-dimensional
moving horizontally from x1 = 0.1 m to x1 = 0.25 m, observer, respectively. It should be stressed that the vibra-
while the lifting unit remained constant at the beam tip, tion rejection control law could have been enabled much
i. e., x2 = L. For this purpose, a PD control law was used earlier, but our purpose was primarily to highlight the be-
for reference tracking of the driving unit, where the de- havior of the observers. A slight difference in the trajecto-
sired trajectory xd1 (t) stems from a double integration of ries is due to two separate closed-loop recordings on the
a trapezoidal acceleration profile. Figure 2 shows a com- real laboratory model.
814 | L. Ecker et al., Observer design for a single mast stacker crane

variant of the Lumer-Phillips theorem according to [16,


Theorem 1.2.4]. Therefore, we consider the state space
X = HC2 (0, L) × L2 (0, L) × ℝ × ℝ, where HC2 = {w̃ ∈
H 2 (0, L)| w̃ Y |0 = 0} because of the boundary condi-
tion (4a), and the state vector χ = [χ1 , χ2 , χ3 , χ4 ]T =
[w,̃ p̃ b , p̃ 1 , p̃ 4 ]T . Note that H l (0, L) denotes a Sobolev space
of functions whose derivatives up to order l are square in-
tegrable. Thus, the state space X is equipped with the nat-
ural (standard) norm

̃ H 2 + ⟨p̃ b , p̃ b ⟩L2 + (p̃ 1 )2 + (p̃ 4 )2


‖χ‖2n = ⟨w,̃ w⟩ (26)

with ⟨w,̃ w⟩
̃ H 2 = ⟨w,̃ w⟩
̃ L2 + ⟨w̃ Y , w̃ Y ⟩L2 + ⟨w̃ YY , w̃ YY ⟩L2 . How-
ever, for our purposes it is of advantage to introduce the
Figure 3: Scenario B: Comparison of the EKF and the pH observer in (energy) norm
a closed-loop vibration rejection scenario with active lifting.
1
‖χ‖2X = EI ⟨w̃ YY , w̃ YY ⟩L2 + ⟨p̃ , p̃ ⟩ 2
ρA b b L
1 1
Remark 4. In general, spillover phenomena in early- + α(w|̃ 0 )2 + (p̃ )2 + (p̃ )2 , (27)
mw 1 mh + mk 4
lumping approaches can lead to drastic problems, e. g.,
the excitation of high-frequency natural oscillations that where we have the equivalence Hẽ = 21 ‖χ‖2X . Since we
can provoke closed-loop instability, see [15]. However, for are able to find constants c1 , c2 > 0 such that c1 ‖χ‖2n ≤
the EKF, which is based on the finite-dimensional model, no ‖χ‖2X ≤ c2 ‖χ‖2n is fulfilled, the energy norm (27) is equiv-
such effects turned out to be crucial. alent to the natural norm (26), cf. Remark 3, and conse-
quently, X serves as a proper Hilbert space equipped with
the inner product ⟨χ, χ⟩̄ X = ‖χ‖2X . Next, to reformulate the
error dynamics as an abstract Cauchy problem of the form
5 Stability investigations χ̇ (t) = Aχ (t), χ (0) = χ0 ∈ X , we introduce the linear oper-
ator A : D(A) ⊂ X → X with
The aim in this section is to present a sketch of the
1
well-posedness and stability investigations of the mixed- w̃ p̃
ρA b
dimensional observer, where we confine ourselves to Sce- [ p̃ ] [ ]
−EI w̃ YYYY
A:[ b ]→[
[ ] [ ]
],
nario A, where the lifting unit is located at the top, i. e., [ p̃ 1 ] [ −EI w̃ YYY |0 − αw|̃ 0 ]
x2 = L. Note that the stability proof for a similar prob- [ p̃ 4 ] [ EI w̃ YYY |L − βw|̇̃ L ]
lem treated within the Stokes-Dirac scenario is presented
in [20]. As a consequence, the PDE (3a) is valid on the do- where D(A) denotes the (dense) domain of A
main D = [0, L], the (error) momentum p̃ 4 can be intro- 4 2 2
duced as p̃ 4 = (mh + mk )ẋ̃ 4 , and therefore, the (error) prin- D(A) = {χ ∈ X |w̃ ∈ (H (0, L) ∩ HC (0, L)), p̃ b ∈ HC (0, L),
ciple of momentum (3e) for the tip mass reads mw m + mk
p̃ 1 = p̃ | , p̃ 4 = h p̃ b |L , EI w̃ YY |L = 0}.
ρA b 0 ρA
(mh + mk )ẍ̃ 4 = ṗ̃ 4 = EI w̃ YYY |L − βw|̇̃ L . (24)
Regarding the Lumer-Phillips theorem [16, Theorem 1.2.4]
The error principle unit for the driving unit follows to it has to be shown that the domain D(A) is dense in X , the
operator A is dissipative and 0 ∈ ρ(A), the resolvent set
(mw )ẍ̃ 1 = ṗ̃ 1 = −EI w̃ YYY |0 − αw|̃ 0 , (25) of A. Similar to [8, Proof of Lemma 2.2], it can be shown
whereas those of the lifting unit can be omitted. that D(A) is dense in X . Furthermore, the equivalence
Hẽ = 21 ‖η‖2X implies ⟨χ, Aχ⟩X = −β(w|̇̃ L )2 , and therefore, it
follows that the operator A is dissipative. To prove that 0 ∈
5.1 Well-posedness investigations ρ(A), it can be shown that for every χ̄ = [χ1̄ , χ2̄ , χ3̄ , χ4̄ ]T ∈ X
we can uniquely solve Aχ = χ̄ for χ = [w,̃ p̃ b , p̃ 1 , p̃ 4 ]T ∈
First, the observer-error dynamics are reformulated as D(A), and verify that A−1 maps bounded set in X into
an abstract Cauchy problem, which allows to apply the bounded set of N = (H 4 (0, L) ∩ HC2 (0, L)) × HC2 (0, L) × ℝ × ℝ,
L. Ecker et al., Observer design for a single mast stacker crane | 815

i. e., A−1 exists and is bounded, and thus, 0 cannot be derived by means of a port-Hamiltonian system represen-
an eigenvalue of A. Consequently, we are able to apply tation. The collocated observer inputs were chosen such
the variant of the Lumer-Phillips theorem according to [16, that the energy functional of the observer-error is non-
Theorem 1.2.4], and thus, the linear operator A is the in- increasing. A sketch of well-posedness and asymptotic sta-
finitesimal generator of a C0 -semigroup of contractions. bility investigations is given for the special scenario with
Moreover, to ensure that the observer state converges to inactive lifting mass at the beam tip. Both observers were
the system state, in the following the asymptotic stability verified in experiments on a laboratory model, where an
of the observer error is verified. acceleration measurement of the beam tip has been ex-
ploited. Finally, we want to stress that the estimated quan-
tities can be successfully used for vibration rejection.
5.2 Asymptotic stability
Next, regarding the investigation of the asymptotic stabil- Funding: This work has been supported by the Austrian
ity of the observer error we use LaSalle’s invariance prin- Science Fund (FWF) under grant number P 29964-N32.
ciple for infinite-dimensional systems, see [17, Theorem
3.64, 3.65], which can be applied since the solution tra-
jectories are precompact. This follows from the fact that
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20. Le Gorrec, Y., Zwart, H.J. and Ramirez, H. (2017). Asymptotic Germany and is currently a Senior Principal Scientist. His topics of
stability of an Euler-Bernoulli beam coupled to non-linear interest include Robot and Motion Control as well as Robot Learning.
spring-damper systems. IFAC-PapersOnLine, 50(1), 5580–5585.

Markus Schöberl
Johannes Kepler University Linz, Institute of
Bionotes Automatic Control and Control Systems
Technology, Altenberger Str. 69, A-4040
Lukas Ecker Linz, Austria
Johannes Kepler University Linz, Institute of markus.schoeberl@jku.at
Automatic Control and Control Systems
Technology, Altenberger Str. 69, A-4040
Linz, Austria
lukas.ecker@jku.at Markus Schöberl received the Dipl.-Ing. degree in Mechatronics in
2004 and his Ph. D. degree (Dr. techn.) in control theory in 2007,
both from the Johannes Kepler University (JKU), Linz, Austria. From
2007 to 2011 he was a Post-doctoral Researcher at the JKU, and from
Lukas Ecker received the Dipl.-Ing. degree in Mechatronics from the 2011 to 2014 he was an APART fellowship holder of the Austrian
Johannes Kepler University Linz (JKU), Austria, in July 2020. He is Academy of Sciences. Since 2014 he is an Associate Professor at the
currently a Ph. D. student at the Institute of Automatic Control and JKU. His research interests include nonlinear control and analysis
Control Systems Technology. His research interests include system of physical systems based on geometric and algebraic methods,
identification and nonlinear observer design. covariant system theory, and Lagrangian and Hamiltonian field
theory.

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