A Mathematical Model of Geared DC Motor Based of Overhead Crane Control System Prototype

Overhead crane system is largely used in the heavy industries as the main part of material handling mechanism. The overhead crane operated by the electric motor and its controller shall fulfill two major requirements which are fast response as well as accurate positioning during moving the goods from one location to another location. However, to simulate the real overhead crane system is tedious and time consuming due to the large structure and safety reasons. Thus, this project will try to simulate the performance of the prototype version of the overhead crane system that has been predicted to perform like the original one but in a small scale. In order to simulate that, a mathematical model of the geared DC motor-based of overhead crane control system prototype shall be formulated. The mathematical model is developed and tested by using Matlab/Simulink  software. The mathematical model is being tested in two conditions, without controller and with controller. To acquire the gain value of the  controller, first method of the Ziegler-Nichols method is applied. The developed model will be verified for various positions and loads. The performance of the model will be measure in terms of the time response which are rise time, peak time, percentage overshoot, and settling time as well as the steady-state error for the position accuracy. The results will confirm that a good mathematical model will give the best projection to imitate the performance of the real size of the overhead crane. Keywords: Geared DC motor, overhead crane system, first method of Ziegler-Nichols, time respond, position accuracy