Interactive simulation of industrial wire-rope cranes: Hoisting, luffing, and slewing motions

This study presents a comprehensive three-dimensional (3D) analysis of wire-rope mechanisms in crane systems, with a particular focus on mobile harbor cranes during luffing, slewing, and hoisting operations. The developed model incorporates bending and transverse vibrations of wire ropes, while accounting for variations in wire-rope length during complex 3D movements. Additionally, a real-time interactive simulation framework is introduced, enabling precise and stable real-time modeling of crane dynamics. This framework integrates a joystick-based control system, allowing users to control virtually crane operations. The accuracy of the real-time interactive simulation is validated against offline simulations. Moreover, the system dynamics are further verified through theoretical analysis. The developed model offers some insights into payload behavior during combined crane operations, addressing potential oscillations caused by the elasticity of the wire ropes and the rigid-body motion of the payload. Furthermore, the mathematical model developed in this study can be used to predict the payload’s motion trajectory, which helps in preventing system failures and damage during complex and heavy-load operations. The proposed framework is applicable across the entire lifecycle of crane systems, from the initial design phase to the final stages of motion control in various transport applications.