Fuzzy PD-Based Control for Excavator Boom Stabilization Using Work Port Pressure Feedback

Hydraulic excavators operate in harsh environments where direct measurement of actuator chamber pressures and boom displacement is often unreliable or infeasible. This study presents a novel control strategy that estimates actuator chamber pressures from work port pressures using differential equations, eliminating the need for direct pressure or position sensors. A fuzzy logic-based proportional–derivative (PD) controller is developed to mitigate boom oscillations, particularly under high-inertia load conditions and variable operator inputs. The controller dynamically adjusts gains through fuzzy logic-based gain scheduling, enhancing adaptability across a wide range of operating conditions. The proposed method addresses the limitations of classical PID controllers, which struggle with the nonlinearities, parameter uncertainties, and instability introduced by counterbalance valves and pressure-compensated proportional valves. Experimental data is used to design fuzzy rules and membership functions, ensuring robust performance. Simulation and full-scale experimental validation demonstrate that the fuzzy PD controller significantly reduces pressure overshoot (by 23% during extension and 32% during retraction) and decreases settling time (by 31.23% and 28%, respectively) compared to conventional systems. Frequency-domain stability analysis confirms exponential stability and improved damping characteristics. The proposed control scheme enhances system reliability and safety, making it ideal for excavators operating in remote or rugged terrains where conventional sensor-based systems may fail. This approach is generalizable and does not require modifications to the existing hydraulic circuit, offering a practical and scalable solution for modern hydraulic machinery.