Single Smooth Waveform Command‐Shaping Control of Overhead Crane Systems Utilizing Two‐Stage Acceleration–Deceleration Profile for Short‐Moving Point‐to‐Point Maneuver

ABSTRACT Modern industrial demand for efficient material handling in confined spaces has driven the need for overhead cranes capable of short‐distance point‐to‐point maneuvers without compromising payload stability. Conventional three‐stage shaper profiles, experiencing acceleration, cruising, and deceleration, become inefficient or infeasible for short distances where cruising speed cannot be reached before deceleration begins. This paper proposes a single smooth waveform command‐shaping controller specifically designed for two‐stage acceleration–deceleration maneuvers when the cruising stage is eliminated due to distance constraints, offering closed‐form coefficients for easy implementation without the need for complex optimization processes. To define where a two‐stage shaper is required, feasibility maps defining operational limits across cable lengths, distances, and time constraints are presented. Experimental validation on a laboratory crane confirms strong agreement with numerical simulations, achieving minimal residual oscillations for short‐distance and rapid‐cycle operations. Sensitivity analysis shows robustness improves with cable length, and the two‐stage shaper outperforms the three‐stage approach under natural frequency variations. The proposed novel two‐stage shaper provides a practical, vibration‐free solution for short‐distance crane operations where total cycle time must be minimized.