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ControlEng. Practice, Vol. 4. No. 5, pp.

645-653, 1996
Copyright 0 1996 Elsevier Science Ltd
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PII:SO967-0661(96)00046-9

CONTROLLER DESIGN FOR AN OVERHEAD CRANE SYSTEM


WITH UNCERTAINTY
Chi-Cheng Cheng and Cheng-Yi Chen
Department of Mechanical Engineering, National Sun Yat-Sen Universiry, Kaohsiung, 80424 Taiwan, Republic qf China
(chengcc@cc.nsysu.edu.tw)

(Received January 1995; infinalfotm December 1995)

Abstract: Overhead crane systems are widely used for material transportation in many industrial
fields. However, undesired oscillation can always be found during the moving process, especially at
the end location of the transport. The swing may extend the carrying time and cause safety
problems. In order to achieve small swing angles, and also to incorporate the potential uncertainty
property of the system, a robust controller has to be developed. Here, a controller, which combines a
feedback linearization approach and a time delay control scheme, is chosen. The time delay control
is applied to complete the feedback linearization for a nonlinear system under the influence of
uncertainty. By suitable definition of system outputs, input/output de-coupling presents a direct
relationship between the system outputs and inputs. Thus, robust cancellation of the uncertainty,
and insertion of the designated dynamics can be accomplished. Encouraging control performance is
shown in the results of a computer simulation.

Keywords: Feedback linearization; nonlinear control; time delay; transportation control;


uncertainty.

1. INTRODUCTION and safety, but will also make the system more
applicable to other engineering scopes.
Overhead crane systems have been widely used for
material transportation in many industrial fields, due Recently, anti-swing control for overhead crane
to their low cost, easy assembly and maintenance. systems has become one of the most popular research
However, severely nonlinear properties bring about topics. Basically, two control schemes, open-loop
undesired swings, especially at take-off and arrival. control and closed-loop control, have been
Most overhead crane systems belong to the category investigated. The open-loop control method only
of incomplete control systems, which only allow a suggests how the cart should move in order not to
limited number of inputs to control more outputs. induce oscillations at the termination point (e.g.,
Such uncontrolled oscillations cause both stability (Aspinwall, 1980; Starr, 1985; Strip, 1988; Meckel
and safety problems. This drawback strongly and Seering, 1985; Karnopp, et al., 1992)).
constrains the operational efficiency and the However, some differences exist between the ideal
application domain. Besides, an overhead crane model and the actual system, and an overhead crane
system may experience a range of parameter system has to encounter disturbances from its
variations. Different loading is the most common environment in the real world. Inaccurate modeling
condition. Therefore, a robust and delicate always induces practical control problems.
controller, which is able to diminish these Therefore, satisfactory performance may not be
unfavorable swing phenomena and manage achieved by applying these open-loop control
uncertainty problems, needs to be developed. A good strategies to an actual system. The closed-loop
control strategy will not only enhance both efficiency methods, given the control criteria, e.g., loading

64.5
646 Chi-Cheng Cheng and Cheng-Yi Chen

conditions, position requirement, and swing angles, hoisting d r u m ~


use feedback techniques to implement different
crab ~-~_ ! !_~_ _ ~
control strategies. Several control structures have
been studied. Sakawa and Nakazumi (1985), and
Sato and Sakawa (1988) presented hybrid control
algorithms for rotary crane systems. A completely
controllable state feedback method was developed for
an overhead crane with a fixed cable length by
Moustefa and Ebeid (1988). Auernig and Troger
(1987), and Hara, et al. (1989) looked at this hook
problem from the optimal control point of view. All tong~ ) steel coil
the control methods mentioned above ignore possible
uncertainty problems. An adaptive control scheme / / / / / / / / / Ground
using feedback linearization and parameter
estimation was presented by Boustany and Fig. 1. Overhead crane system for a factory.
D'Andre'a-Novel (1992). However, control perform-
ance was greatly limited by the convergent speed of
the estimation algorithm. Furthermore, reversed Xp
behavior was usually observed at the beginning stage
u~ FA u lwinch
of control. ~ - - - - - ~ ' - -

/ / / / / / / ~\/ / / / / / /
In order to overcome the strongly nonlinear
properties and possible uncertainty problems in the
system, feedback linearization with a time delay
control algorithm is chosen in this paper. The
feedback linearization transforms complicated
G ~mg
nonlinear systems into simplified equivalent systems
through coordinate transformation. Controller
design is thus based on familiar linear control Fig. 2. Cart-pendulum model with a variable
strategies by cancelling undesired nonlinear parts. pendulum length.
Although the method is potentially applicable to
most nonlinear systems, poor control performance system because it has a smaller number of actuators
ahvays results from uncertainties or unmodeled than the number of controlled variables.
dynamics. The time delay control utilizes state
information with a small time delay, to estimate the In order to simplify the modeling complexity, several
unknown dynamics. It has been shown (Youcef- assumptions have first to be made: (1) Plastic
Toumi and Ito, 1990) that this control scheme deformation in the system is ignored. (2) The cable
produces good disturbance rejection characteristics. is treated as a weightless rigid body. (3) The
The combination of feedback linearization and time moment of inertia of the load is ignored and the load
delay control will be developed for an overhead becomes a point mass. Therefore, the overhead
crane system to achieve a swing-free response under crane system can be simplified to a cart-pendulum
the influence of uncertainty. model with a variable pendulum length, as shown in
Fig. 2. Ul is the force exerted by the horizontal
actuator and u2 is the applied torque from a
2. DERIVATION OF THE DYNAMIC MODEL rotational actuator acting on a winch with a radius R.
The masses of the cart and the load are denoted by M
A two-dimensional overhead crane system, which
and m. xp is the horizontal displacement and 0
has the capabilities of both traversing and hoisting,
is considered in this research. Most crane systems indicates the inclination swing angle. L represents
used for loading and unloading at a dock or for the cable length and J stands for the moment of
assembly in a factory have similar structures.(Fig. 1) inertia of the winch. The kinetic energy and the
potential energy can easily be obtained as follows:
This kind of crane system has two actuators,
responsible for horizontal and vertical motions,
respectively. Nevertheless, three controlled T = 1~MYCp
"2 +~-m[(x
1 "r +/~sinO+LOcos 0) 2

variables, horizontal and vertical displacements as +(Lcos 0 - LOsin 0) 2 + ~ J ( Z / R ) 2 ] (1)


well as the swing angle, need to be equally
considered. This system is an incomplete control V = - m g L . cos 0. (2)
Controller Design for an Overhead Crane System 647

The dynamic equations can therefore be derived by Time delay control (TDC), presented by Youcef-
applying the Lagrangian approach and are described Toumi and his colleagues (Youcef-Toumi and Ito,
by 1990; Youcef-Toumi and Wu, 1992), is designed for
the control of systems with unknown dynamics and
J s i n O ~ _ u . sinO disturbances. This approach uses past observation of
M P R2 - 1+ 7 u2
the system state and control input to calculate the
current control action that can quickly cancel the
msin 0J?p + (m +-~T)L = m(L0~+ gcos 0) - 1 us (3) unknown dynamics and the unexpected disturbance,
simultaneously. Although the time delay control
cos 0p + L 0 = -2/~b - g . s i n 0. sacrifices a little gain margin caused by the inserted
time delay, this method gains good immunity to
uncertainties and disturbances. Hence, the time
Define the state vector x as [xp L 0 fp L ~T and delay control technique can be used to achieve
the input vector u as [u] U2] T. The dynamic input/output linearization without knowing the exact
equations can be converted to a nonlinear state-space model dynamics. The proposed method combines
representation, i.e., systematic design of feedback linearization for
nonlinear systems with the fast convergent property
(4) of the time delay control for unmodeled dynamics.
"~61 = f 6 l +G6lU2xl
where
Consider a square nonlinear system (number of
p control inputs equal to the outputs) described by the
L following nonlinear differential equations
0
mJ.sin0(L b2+g cos &=f(x)+G(x)u
f= Q y=h(x), (5)
mMR 2( LO ~+gcos 0)
Q where x is an n 1 state vector, u=[u~ u2 ... u,,]T is
-mdsinOcos O(LO2+gcos 0) 2LO+gsinO an m x 1 control input, y is an mx 1 output of
QL L interest, and G=[g~ g2 "" g,~],f h are, nm, nl,
0 0 ml nonlinear functions of states in a smooth vector
0 0 field, respectively. Now, the system output can be
0 0 differentiated until control inputs appear.
mR 2 + J mR sin O
Q Q m
G= v (') = L~h, + ~~=l~gy
' I . I n - l h uj (6)
- m R 2 sin 0 - ( m R sin 2 0+ MR) ~i ~ f "~
Q Q
-(mR 2 + J)Lcos 0 -LRmsinOcos O Equation (6) can thus be rewritten in a matrix form
Q Q as

Q = M ( m R 2 + J ) + m J s i n 2 @.

3. CONTROL LAW L
The feedback linearization technique has been = a(x)+B(x)u. (7)
described in detail in many books on nonlinear
control (e.g. (Isidori, 1989; Slotine and Li, 1991)). It is considered that the value of a(x) in equation (7)
The central idea of feedback linearization is to at the present time t is very close to that at time t-2
algebraically transform an original nonlinear system in the past for a small time delay L,
into an equivalent model of a simpler form, and
cancel existing nonlinearities into a fully or partially - . (r)
a ( x , t ) = a ( x , t _ A) = t-.~-B(x't)t-2"ut-x. (8)
linear one, so that linear control techniques can be
applied. Although the method has systematic design Thus, the time delay control law of the input/output
procedures, an exact model of a nonlinear system is linearization can be obtained as follows
not always available, and the measurement of states
is sometimes difficult, As the result, feedback
/4 t ~. n - I t[ - Y'(r)t
- 3. + j~ "/dr - ~ + vr ] , (9)
linearization faces limitations in actual applications.
648 Chi-Cheng Cheng and Cheng-Yi Chen

where /~ is an m x m constant matrix to be linearization is straightforward. The process is


~,(r) described below.
determined, J,-~ is the rth derivative ofy at time t-2,
and u, and u,.x indicate the control input at time t
and t-2, respectively, v, is the reference input at The relative degree of the system is defined by
time t. Since L is a small time delay, it can be differentiating the system output till the control input
assumed to be just one sampling interval. The above appears. After differentiating the system outputs
equation can be rewritten as a discrete form: twice, the following equation can be obtained.

l/(k) -----/~-1 [ _ y ( r ) ( k - 1) +/~. u ( k - 1) + v(k)] ,(10) F Jsin2O - M R sin01


-T (12)
where k denotes the time at the kth sampling instant. JSiQ__COSO -- OSO /'/2

Therefore, by suitable selection of /~ and with a


sufficiently small time delay, the nonlinear system
(5) can be input/output linearized. The stabilization Hence, the relative degree of the system is 4.
condition has also been investigated by the same Because the rank of the control distribution matrix is
researchers. They found that the choice o f / ~ for one, the control inputs u~ and u2 will emerge
stability has to satisfy III - B ( k ) B -1 II-< a _<1, where dependently. Therefore, a new control input needsto
k is less than a positive integer N. be determined. Let U2 be the new control input of
the system. Equation (12) then reduces to

4. CONTROLLER DESIGN

In this section, the control law derived above will be


LL}h2(x)J-L2]u= (13)

used to solve the control problems of the overhead U 2 = - J sinOul


where +U 2
crane system. By a suitable definition of system MR
outputs, input/output de-coupling presents the direct
relationship between the system outputs and inputs. bl _ M R sin_____0and b2 - _h//Rcos 0
Thus, robust cancellation of the system uncertainty O O
and insertion of the designated dynamics can be
accomplished. At the same time, a control goal that A little cancellation is conducted to simplify the
accurately moves an object from one point to above representation by letting Y2 =w~ because of
another, but without extending the carrying time by
doing another process, can be achieved. complexity of the L ~ h ( x ) . The equation (12) can
thus easily be formulated as the following equation:

4.1 Input/output linearization controller design F 1 F- gsinol Fsinl


] =/ . (14)
The control inputs of the overhead crane system L "i)2 L 0 J L 1 3
shown in Fig. 2 are the force and the torque applied
to the platform and the winch, respectively. The The equation above appears as the standard form of
control goals concerned are positioning the dynamic extension. It will be differentiated twice by
suspended object along the horizontal and vertical defining w~, w 2 = ~ig, and ~i,2 as the states and
directions, and suppressing its swing angle during control inputs of dynamic extension. The system
the process of moving. Thus, the overhead crane dynamics can then be decoupled into the following
system can be viewed as an MIMO system. In representation:
general, the input/output linearization method can be
directly applied to decouple square systems into a
direct relationship between system inputs and
outputs. Examining the actual system, two output
y~4) I [a'(x'] w)l+0B(x'w)Fu'
3 Lff 2 (15)

functions are defined by absolute horizontal position


and vertical position of the load given by where
I-(wl - g ) sinO]

Y=
y,]=h(x)=Fxp
Y2
+Lsin01
L L cost~ ] (11)
a(x, w) = / cos o J

L 0 1

Since the output functions of the system have been If B(x,w), the decoupling matrix, is nonsingular,
selected, controller design using input/output then equation (15) is the standard form for
Controller Design for an Overhead Crane System 649
input/output linearization. However, conditions 4.2 Input/output linearization with time delay
exist for B(x,w) becoming invertible. They are controller
L 0, 0 ~ x]2, and w~g. Fortunately, these
conditions are always relevant to actual overhead Since system nonlinearities mainly appear in
cranes. The length of the rope, or the distance equations (13) and (17), the time delay technique is
between the winch and center of the load, can never then applied to them. To estimate the control
be zero. The swing angle of load is not expected to distribution b5 in equation (13), the swing angle of
sway to 90 , and the value of w,, the vertical the load is assumed to be small so that it can be
acceleration, is much smaller than gravity g. As a simplified to b2 =-R/(mR 2+ j ) , which is only related
result of the above analysis, the original system has to the mass of the load. Thus, considering that the
relative degree 4, and 6 states. By undergoing overheadcrane operates in known loading ranges,
dynamic extensions twice, one has relative degree 8, and the constraint of input/output linearization using
and 8 states, where the relative degree of the system time delay control is /~ >_b2/2, /~ can easily be
is equal to the number of the states. Therefore, the selected. Moreover, the constraint of input/output
system can be input/output linearized and decoupled linearization using time delay control in MIMO is
to a completely controllable form of linear system,
IIBi~-~-lll<a<l. B(x) in equation (15) is
i.e., the zero dynamics is never presented with the
estimated by supposing that the swing angle of the
system.
load is very small and the maximum length of the
In controller design for an overhead crane system, rope is known. Hence, /~ can be chosen as a
the type of controller for asymptotic output tracking constant diagonal matrix, and its diagonal elements
is adopted such that the suspended object can be are expressed as (/~11, /~22) to satisfy the above
controlled into a desired smooth trajectory. Now, let criterion. Thus the controller for input/output
the desired trajectory for tracking be [Xd, Zd ]~, and linearization using time delay control can be
define concluded as follows, and its block diagram is
depicted in Fig. 3.
tldd-----[XdZd d Xd Zd Zd Zd Z'd]T. (16)
u, (k) = u, ( k - 1) +/~' x [v, - y l 4~( k - l ) ]
~b2(k)= *b2( k - l ) +/~;) [v 2 -y24)( k - l ) ]
The tracking error, 9 , is defined as the difference
between the desired trajectory Pa and the output, ~i'I (k) = w2(k) (19)
i.e., p-/ad. The controller for input/output U2(k ) = U 2( k - 1)+/~ -1 x [-J)2 (k-1)+w, (k)]
linearization can be designed by letting equation (I 5)
u: (k )=U2 ( k )+ flu~
be equal to [v, v2 ]v. Therefore,
where fl= ( X - x p ) J / ( M R Z ) .
(17)

where ~ overhead
V , = X ~ ' ) - k , ( 2 - 2 ~ ) - k A 2 - 2 ,)-k~(2-~)--k,(x-. G )
]75=~d~')--k I (2"-G)-k~ (2-2~)-k3(2-2~)-k, (Z-Z~)

Id~vativeestimate
Combining equation (17) with the system dynamic ~y,...,y'y
equation (4), gives a stable system with the de-
coupled tracking error described by
Fig. 3. Block diagram for an overhead crane control
system using linearization and time delay
control.
.."
/~l = 95 /~2 = 93 /~3 = 94
~. = v, ~ ~. +k,9. +k293 +k395 +k.9, = 0 4.3 Trajectory design
- - Z (18)
~/5 ~--"9 6 l"/6 = 97 ]"/7 ~-- 98
,,1." To maintain small swing angles during transport,
~8 = v5 ~ ~8 +k,98 +k29, +k396 +k49~ = 0 the desired trajectory should be selected to be as
smooth as possible. Thus, the overhead crane can
650 Chi-Cheng Cheng and Cheng-Yi Chen
30
move smoothly to minimize the swing angle
especially on departure and arrival. A desired
trajectory using the time function can be established.
The desired trajectory is defined as ( X d , Z d ) , such
that the boundary conditions, "~'d=J(d=)(d = Z
(m)
X~4~=0, 2'a =Za =2"~=Z<a4~=0, have to be fulfilled. In
accordance with these conditions, Newton's
interpolation method can be used to generate the 10 [ ---Am_
ed
.near~zedtim
e _ -dalY J
difference table to find the desired time functions:
0 10 20 30
time (sec)
=1"(
126ts/ 420t6 540/7 315ts 70/9 (a)
Xa(t) - - ~ - - - - ~ )D O<_t<T
ID T~ Ts T7 TS T~ 0.06
t>_T
Za(t)=r(126t~j 420t6 540t 7 315t s 70t 9 0,04
--~-- --~
.... )L O<t<T
IL T~ T6 T7 T9 TS 0,02
t>T
(20) O 0.00 t
(rad)
where T is the final time when the overhead crane
-0.02
has reached the target point, and D and L are the
-- - - linearlzed
total distances moved in horizontal and vertical -0.04 ---,dkr---- I~ne arlz4~l ad Ikp IivQ
directions, respectively.
-0.06 "l t J
10 20 30
time (sec)
(b)
5. SIMULATION STUDIES
Fig. 4. Control performance with an actual loading
Three types of the controller, namely input/output
of 8000kg: (a) vertical trajectory of the load,
linearization, adaptive control using feedback
(b) the response of the swing angle.
linearization and estimation design (developed by
Boustany and D'Andre'a-Novel (1992)), and the
input/output linearization using time delay control the dynamics of [ and 0 experience constant
disturbances of 1 rnds z and 0.1 rad/s 2, respectively,
proposed in this paper, were applied to an overhead
crane using computer simulation. The simulation when the simulation time was between 5 and 10
basically corresponds to a medium-sized crane that seconds.
can be found in industry, and which is characterized
by All three controllers achieved good trajectory-
following performance in the X-direction for the first
M = 5000 kg m = 0-10000 kg two cases. This is not surprising, because of the
perpendicular relationship between the horizontal
J = 50 kg.m z R = 0.4 m
motion and the load weight. However, the feedback
g = 9.81 m . s -2 L = 0.5-20 m linearization approach due to the inexact
cancellation of system uncertainty corrupted and
In the third controller, the control distribution moved the suspended objected to the wrong positions
parameters were estimated as /~ = 0.0017, (Figs 4a and 5a). Although the adaptive control
/~, = 5x10 -~, /~22= 1.25. The controller design was using feedback linearization and parameter
based on the expected loading, 5000 kg. The desired estimation could correctly accomplish the task, its
trajectory moving from the starting position, (0, 0, efficiency was limited by bounded convergent rates.
10 m) to the target point, (50 m, 0, 20 m), was given Nevertheless, the feedback linearization using time
by two ninth-order time functions. During the delay control perceived the outputs and the inputs of
simulation, the Runge-Kutta method was used to the system at one time step in the past, and
solve the model equations, and a uniform step size of determined the control action that should be
0.01 second was chosen. commanded at the present time. This control
technique appeared to be superior to the other two
In order to verify the robust properties of the methods. As to the responses of the swing angle, the
controller, three cases of system uncertainty were three controllers behaved similarly, as shown in
examined. They are (1) actual loading is 8000 kg Figs 4b and 5b. It seemed that the pure input-output
which is heavier than the rated value (Fig. 4), (2) linearization in Fig. 5b achieved better results,
actual loading is 8000 kg and parameters o f f in despite the failure of the trajectory control in the Z-
equation (4) are increased by 100%, (Fig. 5), and (3) direction. Since the vibration angles were kept small
enough through the transport process, cancellation of
Controller Design for an Overhead Crane System 651

80 50
.
P

4O
60

30
X~
( mZ) 40 ~ ...,,i=.~
~nllrized+ldeptive 1 (m)
gnellrized *lime dqllmy 2o

lO
20_

o
I
0 10 20 30 lO 20 30
time (sec) time (see)

(a) (a)
0.03 2.0

- - - bne~rized
0.02 I ~ne=,,zed=daptJve
~eaflZed +~ 8 d~y

0.01 ~-
1.0
0 X-X d

(red) -0.010'0 " "'"l ,,' (m) O.S

* -- -- -- Itflelrize d
-- * ~ linelrized+adlplive 0.0,
-0.02 + tlnelrized+um ii de~ay

I -05 ~
-0.03 11 20 310 o
1
lO
time
2"
(sec)
3~
time (see)
(b)
Fig. 5. Control performance with an actual loading
of 8000kg and parameters o f f in equation (4)
increased by lOON: (a) vertical trajectory of I 0
,' ,i ~me l f ~zecl*=d&plive
f~' knel~,zed+time detay

the load, (b) the response of the swing angle.

the nonlinearities was almost achieved. The


(m) o.o. : "~
estimation algorithms of the other two control
methods, trying to determine these unknown
-0.5
uncertainties and dynamics, degraded the angle
responses due to coupling effects, and produced -1.0 J .d , 1
1 20 30
larger vibration amplitudes. Therefore, pleasing time (see)
performance can be expected in the swing angle. (c)
In the third case, shown in Fig. 6, constant 0.15 - -

?
7
disturbances were directly embedded in the system - - - I,ne=r,zea i

within a specific time interval. The first two 0.10


knesrlzed a dapt Ne
Kneel;zeal+time delay
/
methods failed to maintain the overhead crane on the
track when the system encountered such unknown 0.05

disturbances. However, those unknown amounts 0


(red) O.OOA
could be quickly estimated by the time delay
controller and exact nonlinearity cancellation was
-0.05
generally achieved. Hence, satisfactory control
performance was found in both directions. Despite -O10 I 1
2O 3O
not adjusting the controller gains or identifying the time (sec)
system parameters, performance of this controller (d)
was almost independent of the unmodeled dynamics.
Besides, equation (19) indicates simple structure of
Fig. 6. Control performance with a constant
this controller, and the computational load appears
extremely economical. Nevertheless, there was disturbance within 5 and 10 seconds: (a)
always a startup period where the error was desired horizontal trajectory, (b) horizontal
tracking error, (c) vertical tracking error, (d)
relatively large. This is because the system adopted
a backward difference estimator, and was initially at the response of the swing angle.
rest, such that the derivatives of the outputs changed
rapidly when motion commenced.
652 Chi-Cheng Cheng and Cheng-Yi Chen
0.01
process and overcome possible loading uncertainty.
This control scheme combines the systematic design
of feedback linearization for nonlinear systems, and
the fast convergent property of time delay control for
unknown dynamics.
(m)X'b.oo
X-

Simulation results indicate promising and robust


control performance, even for different loading
conditions and uncertain parameter problems.
Compared with a pure feedback linearization method
and feedback linearization with self-tuning control,
-0.01 L I , I t 1
0 10 20 30 the proposed approach also showed satisfactory
time (see)
(a) transient responses and excellent steady-state
properties. However, two limitations to using this
0.2 approach exist. The first is that the decoupling
matrix in feedback linearization has to satisfy the
constraints of a finite, known relative degree of the
system, and stable internal dynamics. The second is
0.1
that measurement of state derivatives, which may be
Z-Z d
difficult in practice, will be a major obstacle to its
(m) use in the real world.
O0

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-0.1 , [ , [ b I Aspinwall, D.M. (1980). Acceleration profiles for


0 10 20 30
time (sec) minimizing residual response. Journal of
Co) Dynamic Systems, Measurement, and Control,
Fig. 7. Control performance with a measurement 102, 3-6.
noise: (a) horizontal tracking error, Co) vertical Auernig, J.W. and H. Troger (1987). The optimal
tracking error. control of overhead cranes with hoisting of the
load. Automatica, 23, 437-447.
Measurement noises usually exist in realistic Boustany, F. and B. D'Andre'a-Novel (1992).
applications. White Gaussian noises with a standard Adaptive control of non-completely controlled
deviation or= 0.1 were added to the measurements of mechanical system using dynamic feedback
2, X, and 2". Therefore, the noise in the estimation linearization and estimation design. Interna-
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