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Outrigger Force Measure for Mobile Crane Safety Based on Linear

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Article  in  Mechanics Based Design of Structures and Machines · April 2010

DOI: 10.1080/15397730903482702

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 Mechanics Based Design of Structures and Machines

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Outrigger Force Measure for Mobile Crane Safety

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Based on Linear Programming Optimization

Shyr-Long Jeng , Chia-Feng Yang & Wei-Hua Chieng

To cite this article: Shyr-Long Jeng , Chia-Feng Yang & Wei-Hua Chieng (2010) Outrigger Force
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Measure for Mobile Crane Safety Based on Linear Programming Optimization , Mechanics
Based Design of Structures and Machines, 38:2, 145-170, DOI: 10.1080/15397730903482702

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 Mechanics Based Design of Structures and Machines, 38: 145–170, 2010
Copyright © Taylor & Francis Group, LLC
ISSN: 1539-7734 print/1539-7742 online
DOI: 10.1080/15397730903482702

OUTRIGGER FORCE MEASURE FOR MOBILE CRANE

SAFETY BASED ON LINEAR PROGRAMMING
OPTIMIZATION#

Shyr-Long Jeng,1 Chia-Feng Yang,2 and Wei-Hua Chieng2

1
Department of Automatic Engineering, Ta Hwa Institute of Technology,
Downloaded by [National Chiao Tung University ] at 10:20 14 February 2016

Qionglin Shiang Hsinchu County, Taiwan, Republic of China

2
Department of Mechanical Engineering, National Chiao Tung University,
Hsinchu City, Taiwan, Republic of China

This work presents a linear programming simplex method for evaluating allowable
reaction forces of multiple outriggers with stability constraints. Minimum/maximum
pruning approach is adopted to increase the computational efficiency of assessing the
outrigger forces when a mobile crane is kept level by the supports of four outriggers.
Determining the outrigger forces is an effective means of preventing a mobile crane
from tipping over or outrigger failures. Two indices, i.e., moment-index and force-
index, which quantify the tendency of tip-over behavior of mobile cranes and examine
the bearing capacity of outrigger, are introduced to improve the safety measures. The
safety hoist criteria of two mobile crane types equipped with different outriggers are
analyzed to demonstrate the feasibility of the proposed scheme. An intelligent anti-upset
device that utilizes the outrigger-based stability measures and selectively suppresses
critical steering commands in real time is implemented to ensure safe crane operations.

Keywords: Linear programming; Mobile crane; Overturning stability.

INTRODUCTION
Mobile crane stability is an extremely important safety issue. Failure to
maintain stability is associated with serious accidents that can injure operators
or damage equipment. Mobile crane accidents depend on a number of factors,
including poor ground conditions, failure to use or fully extend outriggers or
stabilizers, failure to level the crane, rapid slewing, and high-wind conditions.
Statistics (Neitzel et al., 2001) show that at least 50% of crane accidents occur
because mobile cranes or outriggers are not operated properly.
Some investigations have quantified overturning stability of mobile vehicles
or slow-moving legged machines. McGhee and Frank (1968) developed a static
stability margin for an arbitrary support base, which is equal to the shortest distance
from the vertical projection of the gravity center to any point on the support

Received June 4, 2008; Accepted October 10, 2008

#
Communicated by S. Azarm.
Correspondence: Shyr-Long Jeng, Department of Automatic Engineering, Ta Hwa Institute of
Technology, No. 1, Dahua Road, Qionglin Shiang Hsinchu County, Taiwan 30740, Republic of China;
E-mail: [email protected]

145
 146 JENG ET AL.

base boundary. Mezzuri and Klein (1985) extended the stability margin to account
for the effects of rough terrain when moving a base manipulator. A quantitative
measure, termed the energy stability margin, is confined to the stability analysis
of vehicles that are subject to gravity. Nagy et al. (1994) and Ghasempoor and
Sepehri (1998) utilized the energy-based stability measures on the locomotion of
multi-legged robot or heavy-duty manipulator machines, respectively. Sugano et al.
(1993) developed zero-moment criterions to distinguish the stability in controlling
mobile manipulator. Lim et al. (2004) employed zero-moment point theory to
analyze the tip-over stability for a hydraulic excavator. Papadopoulos and Rey
(2000) presented the force-angle stability margin measure operating over uneven
terrain. These stability measures have typically assumed that the manipulator stands
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on solid ground. Although the overturning stability of the crane has received
considerable attention, the extent to which ground conditions or outrigger legs
collapsed has not been addressed.
Tamate et al. (2005) examined a serial of experimental analysis to investigate
the influence of outriggers penetrating the ground on mobile crane stability. Kato
and Ito (1980), who analyzed the static stability of a crane carrier, proposed a
theoretical formula that explains the elastic deformation of carriers. Dubowsky et al.
(1991) developed an analysis method of dynamic spatial behavior by considering
the flexibility of the manipulators. Mijailovic and Selmic (2004), Aslan et al. (1999),
and Towarek (1998) examined angular ball bearing deformation, flexible booms,
and soil, respectively. Abo-Shanab and Sepehri (2005) demonstrated manipulator
movements, the contact between the base and ground, hydraulic compliance, and
frictional properties between wheels and ground on tip-over stability of heavy-duty
hydraulic log-loader machines. These studies (Abo-Shanab and Sepehri, 2005; Aslan
et al., 1999; Dubowsky et al., 1991; Kato and Ito, 1980; Mijailovic and Selmic, 2004;
Towarek, 1998) described the combined vehicle suspension-ground-outrigger by
using the spring-damping model, which is appropriate for off-line analysis. Ground
conditions can vary dramatically from one workplace to another, and even within
the same workplace. Soils range from wet sand that can only support 2,000 pounds
per square foot to dry hard clay that can support 4,000 pounds per square foot to
a well-cemented hardpan that can support as much as 10,000 pounds per square
foot. In the workplace, accurately obtaining the coefficients of spring and damping
is rather difficult. Evaluating the reaction forces while assuming that the ground
conditions remain the same irregardless of location would be unreasonable.
Capable of determining lifted capacities of a crane by using load charts
or mathematic equations calculated by the ratio of the overturning moment and
stabilizing moment, conventional antiupset devices (Al-lami and Benazzouz, 1991;
Neitzel et al., 2001; Queensland Government, 2006; Truninger, 1992) provide crane
operators with a warning signal if the overturning moment required to upset the
crane is approached or exceeded. Although the overturning stability of the crane
has received considerable attention, outrigger forces-related information is missing
except that the force sensors of the outrigger are provided. While Zhou et al.
(2007) proposed a safety system that detects hydraulic outrigger forces by a force
transducer, that system cannot accurately predict the lifted load, boom angles, and
load radius based on the distributions of outrigger forces. Studying addition to
evaluating the allowable reaction outrigger forces, this work accurately predicts the
risk of overturning for a mobile crane. Real-time monitoring of outrigger capacities
 OUTRIGGER FORCE MEASURE FOR MOBILE CRANE SAFETY 147

provides crane operators with relevant information to perform hoist operations

safely and efficiently.

MATHEMATICAL MODEL OF MOBILE CRANE

Figure 1 presents an appearance of a mobile hydraulic crane, which is
set horizontally on plat ground. Taking the plat ground as the datum level, a
rectangular coordinate with X-, Y -, and Z-axis is setup at the intersection with the
rotational center axis. The following discrete components of the mobile crane are
identified: the gravitational force of the lower machine is assumed as Fweight with the
gravitational center at
xweight  yweight ; the gravitational weight of a lifted load is Fload
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at position
xload  yload ; the gravitational force of each section of the telescopic boom
is Fpbj (j = 1     m with the corresponding gravitational center at
xpbj  ypbj ; the
three components of reaction forces acting on each outrigger are
Rix  Riy  Riz 
i =
1     n, where n is the total number of outriggers; and, each outrigger position
under the contact point is at
xRi  yRi .
Feqx  Feqy  Feqz  and
Meqx  Meqy  Meqz  are
the equilibrium force and moment due to centrifugal force, harmonic loads induced
by rapid loading at the hook, and strong wind imposed on the rotational center. For
a rigid body to be in equilibrium, the net force and net moment on the crane body
must equal zero. This equilibrium condition can be represented using the following
equations:

n
Fx = Feqx + Rix = 0 (1.a)
i=1

Figure 1 Mechanical model of a mobile crane.

 148 JENG ET AL.

n
Fy = Feqy + Riy = 0 (1.b)
i=1



m

n
Fz = −Fload − Fweight − Fpbj + Feqz + Fiz = 0 (1.c)
j=1 i=1



m
Mx = −Fload · yload − Fweight · yweight − Fpbj · ypbj
j=1

n

n
+ Meqx + Riz · yRi + Riy · h = 0 (1.d)
i=1 i=1



m
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My = Fload · xload + Fweight · xweight + Fpbj · xpbj

j=1

n

n
+ Meqy − Riz · xRi − Rix · h = 0 (1.e)
i=1 i=1



n

n
Mz = Meqz − Rix · yRi + Riy · xRi = 0 (1.f)
i=1 i=1

where h is the height between the contact point and the rotational center. These
equations, which can be rewritten with unknowns Riz (i = 1     n on the left side
and given input variables on the right side, are solved for vertical reaction forces at
each outrigger using matrix manipulation.
 
  R1z  
1 1 ··· 1 R  F
xR  2z  allz
xR2 · · · xRn     = Mally   (2)
yR1 yR2 · · · yRn   
1 
Mallz
Rnz

where


m
Fallz = Fload + Fweight − Feqz + Fpbj 
j=1

m
Mally = Fload · xload + Fweight · xweight + Fpbj · xpbj + Meqy − Feqy · h
j=1

m
Mallx = Fload · yload + Fweight · yweight + Fpbj · ypbj − Meqx + Feqx · h
j=1

Outrigger Reaction Forces

Overturning stability of a mobile crane determined using the outrigger forces
is similar to the stability criterion defined based on ground condition. The outrigger
force Riz can be represented in such a way that its positive value corresponds to
ground deflection. When the outrigger force Riz is negative, support loss occurs.
Overturning stability can be established by determining whether the forces within a
feasible region, are higher or lower than zero.
 OUTRIGGER FORCE MEASURE FOR MOBILE CRANE SAFETY 149

Lemma. If outrigger forces with nonnegative values satisfy static equilibrium in (2),
then the mobile crane is stable; otherwise, the mobile crane is unstable.

When outriggers are operated at more than three positions, the static behavior
of a mobile crane is an underdetermined linear system, for which number of static
equations is less than unknown. Vertical reaction force Riz cannot be determined
directly using only the equilibrium equation in (2). At least one solution for reaction
forces can satisfy the equilibrium equation when the underdetermined system is
consistent with the stability constraints. Accessing allowable reaction forces of
multiple outriggers requires evaluating all possible outrigger forces. Instead, a
scheme assessing the allowable ranges of outrigger forces increases computational
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efficiency as described below.

Multiple Position Stabilizer Legs

A mobile crane is kept level using n outriggers, where n is greater than three.
Rearranging the lasting terms of outrigger forces Rkz , k = 4     n into the right
side of (2) converts a system of three equations with n unknowns into the following
equivalent form:
    F − n R 
1 1 1 R1z allz k=4 kz
  
xR xR2 xR3  R2z  = Mally − nk=4 Rkz · xRk   (3)

1
yR1 yR2 yR3 R3z M − n R ·y
allx k=4 kz Rk

Using Cramer’s rule, outrigger forces Riz (i = 1 2 3) can be derived using

determinants
 Q1 −n Rkz ·1k 
k=4
  R1 R2 R3
R1z  
 n 
R2z  =  Q2 − k=4 Rkz ·2k   (4)
 
 n 
R1 R2 R3
R3z Q − R ·3 k=4 kz 3k
R1 R2 R3

where

Qi = −Mally
xRi+1 − xRi+2  − Mallx
yRi+2 − yRi+1 

− Fallz
xRi+2 · yRi+1 − xRi+1 · yRi+2 
1k = Rk R2 R3 
2k = R1 Rk R3 
3k = R1 R2 Rk 

1 1 1

Ri Rj Rk = xRi xRj xRk 

yR yR yRk
i j
 150 JENG ET AL.

To stop a crane from turning over, outrigger forces must be greater than or equal
to zero. These constraints on outrigger force variables can be rewritten as

Qi − nk=4 Rkz · ik
≥ 0 for i = 1 2 3 (5.a)
R1 R2 R3

Rkz ≥ 0 for k = 4     n (5.b)

The outrigger forces, Riz , i = 1     n, are chosen as the design variables whose
value can be randomly selected from the inequality constraint set in (5). If
the constraint set is found to be feasible, the lower and upper bounds of
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each outrigger force may be obtained. When the set of feasible solutions is
empty, the outrigger forces fail to satisfy the constrain set and make the crane
overturning. The problem of obtaining the lower limit of outrigger forces Riz can
be formulated by considering the outrigger forces Riz as the objective function.
The design objective is to minimize the outrigger force Riz and, simultaneously,
satisfy the inequality constraint set. Similarly, no restriction, such as upper limit
of the outrigger force Riz , is the same as maximization of the outrigger force.
The formulation has n design variables and n inequality constraints. A set of
2*n independent objective functions is utilized to derive the smallest and largest
allowable values for each outrigger force Riz . The optimum problem, including
multiple linear objective functions and linear constraint functions, is a linear
programming problem. The optimum solution for a linear programming problem
always resides on the boundary of a feasible region. The two-phase simplex
algorithm (Siddall, 1972) is applied to find the lower and upper bounds of each
outrigger force.

Four-Point Outrigger System

Consider a mobile crane is generally setup using four outriggers, each located
at a corner. The procedure to determine the available ranges of the outrigger
forces can be simplified by using a minimum/maximum operation discussed below.
According to (4), the unknown variables R1z , R2z , and R3z can be expressed as
follows:
 Q1 −R4z ·14 
  
R1z  R1 R2 R3 
 
R2z  =  Q2−R4z ·24   (6)
 R1 R2 R3 
R3z  
Q3 −R4z ·34
R1 R2 R3

The fundamental geometric meaning of the absolute value of Ri Rj Rk is equal to

the area of a triangular formed by supporting outriggers Ri , Rj , and Rk . According
to Lemma, all outrigger forces Riz should be nonnegative for a stable solution of
a mobile crane. That is, constraints on outrigger force Riz , i = 1 2, and 3 can be
 OUTRIGGER FORCE MEASURE FOR MOBILE CRANE SAFETY 151

rewritten as the following inequalities:

Q − R · 

 1 4z 14
≥0



  R1 R2 R3

Q − R · 
2 4z 24
≥0  (7)

 


R1 R2 R3

 Q − R4z · 34

 3 ≥0
R1 R2 R3

The constraints are represented by inequalities, each related to a feasible range of

static stability, yielding lower and upper bounds of outrigger forces.
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Notably, inequality of R4z ≥ 0 yields outrigger force variable R4z , including a

lower bound value of zero. To establish an arbitrary starting algorithm, this study
may initiate the upper and lower bounds of outrigger force of R4z into  and
0, respectively. When the value for 14 /R1 R2 R3 is positive, the inequality of (7)
becomes
Q1
R4z ≤  (8)
14

A new upper bound of outrigger force R4z , denoted by R4max , must be restricted by
using the minimum operation
 
Q
R4max = min R4max  1  (9)
14

Similarly, the lower bound for outrigger force R4z , denoted by R4min , may be pruned
the retrieval region for the case when 14 /R1 R2 R3 is a negative number.
 
Q
R4min = max R4min  1 (10)
14

Different values of 14 /R1 R2 R3 yield rigorous upper and lower limits on the
outrigger force value, R4z . The procedure reduces two bounds until available states
satisfy the set of inequalities constraints in (7). The lower bound of outrigger force
R4z must be less than or equal to the upper bound of outrigger force R4z . If the
feasible region of outrigger force R4z is null, then no solution satisfies the static
equilibrium and the mobile crane is unstable. This minimum/maximum procedure
determines the overturning stability as listed in the Appendix.

Moment and Force Indices

The stabilizing moment, which typically keeps the crane upright, can be
expressed as follows (Fig. 2):

Mstablize = Fweight · dweight  (11)

 152 JENG ET AL.
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Figure 2 The stabilized and overturning moments.

and the overturning moment, which generally tips the crane over, is

n
Moverturn = Fload · dload + Fpbi · dpbi  (12)
i=1

where dweight , dload , and dpbi are the perpendicular distances between the overturning
edge connected by the rear two outriggers and projection points Fweight , Fload , and
Fpbi forces, respectively. The tipping load, Floadtip , is a critical load lifted, in which
the overturning moment Moverturn is equal to stabilizing moment Mstablize , i.e.,
n
Fweight · dweight − i=1 Fpbi · dpbi
Floadtip =  (13)
dload

The maximum bearing capacity Rcrit between outrigger and ground can be
determined by the maximum axial load of the outrigger provided by the crane’s
manufacturer, or the resistant strength of the current ground type. Two relative
stability indices for risk evaluation of instability of a mobile crane are defined as
follows:
Fload
Smoment = (14)
Floadtip
 OUTRIGGER FORCE MEASURE FOR MOBILE CRANE SAFETY 153

and
max
R1zmax  R2zmax      Rnzmax 
Sforce =  (15)
Rcrit

The moment index Smoment , which is the ratio of current load lifted to tipping
load, is utilized to measure overturning tendency. When the current load lifted is
less than the tipping load, i.e., the Smoment index is less than unity, the stabilizing
moment Mstablize provides a sufficient moment to prevent overturning. Conversely,
when the load lifted increases close to the tipping load, the stabilizing moment
Mstablize resisting overturning becomes gradually inadequate such that the margin
against failure decreases for the entire machine. The force index Sforce is the ratio of
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maximum allowed outrigger forces to the outrigger limit Rcrit  When the maximum
outrigger force exceeds the mechanical limit or the ground strength, outrigger legs
may become cracked. As these two indices increase, the stability of the crane
decreases.

CASE EXAMPLES
Example 1: Mobile Rotary Crane with Four Outriggers
An 18-ton hydraulic mobile crane has a telescopic boom consisting of four
segments (Fig. 3). Maximum boom length is 30.6 m and the rigid boom weighs
approximately 2.8 tons. Each outrigger is extended to 2.1 m outwardly. Dynamic
effects are neglected by assuming that the mobile crane operates at a slow speed.
Table 1 lists the basic numerical data for the mobile crane.
The boom and four outriggers are fully extended and the boom angle is set
at 25 . The resulting outrigger forces are symmetrical to the longitudinal axis of the
mobile crane carrier with the boom located on the front, as shown in Fig. 4. The
upper bounds of outrigger forces on the font pair of outriggers gradually increase to
resist overturning when the load lifted is increased incrementally. The upper bounds
of outrigger forces on the rear pair of outriggers are inversely correlated with the
lifted load and, therefore, reduce to zero. The progressive restriction of the feasible
ranges between the upper and lower bounds abruptly diminishes when the load
lifted exceeds 25 tons. In this scenario, the font outriggers carry the total weight of
the crane and load, and the rear outriggers may lift off the support surface. The
maximum outrigger force is approximately 23.5 tons. The boom configuration can
cause the crane to tip over in the forward direction when the load lifted exceeds the
tipping load Floadtip of 25 tons.
Figure 5(a) presents a polar plot of the moment index Smoment versus rotation
angle  of the upper rotary crane body when the crane is supported on fully
extended outriggers and the telescopic boom is 9.32 m. The assumed lifted load is
25 tons. The radius of the polar diagram is proportional to the value of moment
index Smoment , and curves are graphed at the boom angles  of 0 , 20 , 30 , and 40 ,
respectively. The reduction in the boom angle  is strongly correlated with the fact
that lowering the main boom increases the moment index Smoment . The crane looses
stability when the moment index Smoment lies outside the unity circle. The moment
index is relatively larger near the rotation angles  of 0 , 90 , 180 , and 270 than
 154 JENG ET AL.
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Figure 3 A mobile crane equipped with four outriggers.

that near the rotation angles  of 45 , 135 , 225 , and 315 . Figure 5(b) presents the
polar plot of force index Sforce versus rotation angle  As operating a boom at an
angle <20 results in unstable conditions in some rotation angles, which indicates
that no solutions exist for maximum allowable outrigger forces, and the force index
Sforce is unavailable (Fig. 5(a)). To determine force index Sforce for crane functions
equally with full 360 rotation, the boom angle  is lifted up at 30 , 40 , 50 , and 60 .
The force index is large near rotation angles  of 45 , 135 , 225 , and 315 , where
the boom positions are toward the four extended outrigger locations. One way of
 OUTRIGGER FORCE MEASURE FOR MOBILE CRANE SAFETY 155

Table 1 Numerical data of the mobile crane equipped with four outriggers

Nomenclature Representation Numerical data

Fweight Weight of the crane 18.08 (tons)

Fpb1 Weight of the first segment of boom 1.37 (tons)
Fpb2 Weight of the second segment of boom 1.03 (tons)
Fpb3 Weight of the third segment of boom 0.76 (tons)
Fpb4 Weight of the forth segment of boom 0.60 (tons)
Rcrit Maximum reaction forces of outrigger 40 (tons)
Feq Equilibrium force 0 (tones)
Meq Equilibrium moment 0
Llength Length of mobile crane 6.42 (m)
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Lwidth Width of mobile crane 2.10 (m)

Lradius Radius of turn table 2.52 (m)
Lboom1 The first segment length of boom 9.32 (m)
Lboom2 The second segment length of boom 7.12 (m)
Lboom3 The third segment length of boom 7.10 (m)
Lboom4 The forth segment length of boom 7.10 (m)
Lspan1 The first lateral distance of outrigger 0.85 (m)
Lspan2 The second lateral distance of outrigger 0.65 (m)
Lspan3 The third lateral distance of outrigger 0.6 (m)

increasing moment stability is by rotating the boom toward the support positions
of outriggers as the horizontal distance between the overturning edge and the lifted
hook decreases. However, the distribution of total weight is concentrated on one
outrigger, which reflects the increase in force index Sforce  When continued operation

Figure 4 Four outrigger forces.

 156 JENG ET AL.
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Figure 5 Moment/force indices under various boom angles for the mobile crane equipped with four
outriggers.

shifts the load back to the jack, the loaded outrigger may not have been able to
support the total weight, resulting in or increasing crane instability.
Figure 6 shows the set of feasible symmetrical configurations about the
midline of the mobile crane with outriggers extended 70%, 80%, 90%, and 100%
laterally. The telescopic boom with minimum length assumes an angle of 45
relative to horizontal. The crane is lifting 25 tons. The supplementary extensions of
the suspension scaffolds generate significant additional transverse stability against
overturning. The outriggers extended in the transverse direction have no effect on
 OUTRIGGER FORCE MEASURE FOR MOBILE CRANE SAFETY 157
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Figure 6 Moment/force indices under various lateral distances of outriggers for the mobile crane
equipped with four outriggers.

longitudinal overturning resistance when the lifting operation is in the longitudinal

direction of the carrier. In the same longitudinal direction, another index for
measuring outrigger forces produces a reversal effect by increasing all outriggers
spreads. Force index Sforce retains the same value, whereas rotational angle  remains
within an approximate range of −45–45 or 135–245 . A retractable outrigger is
employed to increase scaffold base width and provides maximum stability when the
boom points in a direction of the sliding outrigger that has the greatest extension.
The working radius, which is the horizontal distance from the crane rotational
center to the boom tip can be approximately calculated using boom length, boom
angle, and standard geometric principles when the boom tip deflection and fly jib
offset are ignored. A safe working area is a visual representation of the orientation
 158 JENG ET AL.

angle  of the upper rotary crane body in relation to the working radius. The crane
is operated safely when a lifted load is below the safety limit at a working radius.
Figure 7(a) presents simulation results for safe working areas when the mobile crane
is configured to lift various loads with fully extended outriggers. The safe working
areas, symmetrical about the midline of the mobile crane, are extremely similar to
the convex area formed by outrigger connection lines. Since the working radius is set
to account for force indices, the four corner regions of working areas are removed
to prevent a heavy load from being concentrated on a single outrigger when the
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Figure 7 Safe working areas of the mobile crane equipped with four outriggers.
 OUTRIGGER FORCE MEASURE FOR MOBILE CRANE SAFETY 159

load lifted exceeds 20 tons. Lift capacity decreases as safe working area increases.
Figure 7(b) plots safe working areas versus outrigger positions when lifting 25
tons. The outrigger transversal spreads provide an additional safe working area in
the transversal direction. The safe working area along the longitudinal direction is
independent of extended outriggers. The four corner regions in the rectangular safe
working area are restricted as the vertical reaction force of an outrigger markedly
exceeds the mechanical limited axial load Rcrit of 40 tons.
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Figure 8 A truck-mounted crane with six supporting points.

 160 JENG ET AL.

Example 2: Truck-Mounted Crane with Six Supporting Points

Figure 8 presents a crane mounted directly onto a rubber-tire truck that drives
around for maximum portability. A pair of outrigger assemblies stabilizes the truck-
mounted crane. This crane is generally designed such that vehicle wheels provide
stability with additional assistance. Table 2 summarizes the mechanical data for the
following simulation.
The telescopic boom with a length of 5.5 m and a boom angle of 10 operates
toward the right side of the truck. The rotation angle  is 0 and the two outriggers
are fully extended. Figure 9 shows the relationships between allowable vertical
reaction forces of six support points and the external load lifted. As the load lifted
increases, the upper bounds of outrigger forces on support points R1 , R3 , and R5 are
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monotonic decreasing functions of the lifted load, and the upper bound of outrigger
forces on support point R4 is a monotonic increasing function. The upper bounds of
outrigger forces on support points R2 and R6 decrease before increasing. When there
are more than four support points, the maximum allowable outrigger forces for the
support points are not monotonic functions and typically increase or decrease in
only one direction as the load lifted increases. In this case, the outrigger forces of
points R1 , R2 , R3 , and R5 decrease gradually and, therefore, decrease to zero. Total
weight of the lifted load and crane are concentrated onto areas covered by support
points R4 and R6 when a tipping load of 4 tons is applied. The crane losses stability
and the wheels and outrigger at points R1 , R2 , R3 , and R5 lift completely off the
ground. Maximum outrigger forces on support points R4 and R6 are about 10.0 tons
and 2.9 tons, respectively.
Figure 10 presents two polar plots that visually represent the orientation of
the rotary crane in relation to moment and force indices. The crane is supported
on fully extended outriggers and minimum boom length is assumed. The moment
index is greater than unity when the crane operates with a rotation angle  between

Table 2 Numerical data of the truck-mounted crane with six supporting points

Nomenclature Representation Numerical data

Fweight Weight of the truck-mounted crane 8 (tons)

Fpb1 Weight of the first segment of boom 0.3 (tons)
Fpb2 Weight of the second segment of boom 0.25 (tons)
Fpb3 Weight of the third segment of boom 0.23 (tons)
Fpb4 Weight of the forth segment of boom 0.2 (tons)
Rcrit Maximum reaction forces of outrigger 10 (tons)
Feq Equilibrium force 0 (tones)
Meq Equilibrium moment 0
Lwidth Width of the truck-mounted crane 1.4 (m)
Lboom1 The first segment length of boom 3.41 (m)
Lboom2 The second segment length of boom 2.09 (m)
Lboom3 The third segment length of boom 2.19 (m)
Lboom4 The forth segment length of boom 2.28 (m)
Lspan1 The first lateral distance of outrigger 0.31 (m)
Lspan2 The second lateral distance of outrigger 0.44 (m)
Lspan3 The third lateral distance of outrigger 0.35 (m)
Lspan4 The forth lateral distance of outrigger 0.3 (m)
 OUTRIGGER FORCE MEASURE FOR MOBILE CRANE SAFETY 161
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Figure 9 Allowable vertical reaction forces on the six supporting points.

50–130 and boom angle  is <50 (Fig. 10(a)). The force index is assumed to be
0 within the unstable regions (Fig. 10(b)). An increase in the boom angle increases
stability. Full orientation angles of the rotary crane body should be avoided as
far as practically possible because the stability of the truck-mounted crane may be
significantly reduced when a load is swung from a crane side to the font. Such
movement decreases stability and markedly enhances the tendency of the crane to
roll under font loading.
Figure 11 shows the set of feasible symmetrical configurations about the
midline of a mobile crane. The crane is lifting 2 tons and the boom is retracted to
its minimum length and the boom angle is 10 . The set of outriggers has movable
lateral extensions of 70%, 80%, 90%, and 100% on the two truck sides. The moment
index Smoment remains the same when the rotational angle  is within an approximate
range of 245–295 or 55–125 . Depending on boom position, the outriggers extended
beyond the vehicle perimeter provide moment stability by simply moving the edge
of overturning relatively closer to the load. Adjustable outriggers provide stability
for left-rear or right-rear loading.
Figure 12 presents the safe working areas versus lifted load and outrigger
lengths. The working area is restricted when the crane operates in the front area.
The working radius varies markedly for rotation angles of 15 , 50 , 130 , 165 ,
250 , and 290 , where direct to the positions of the six support points. Because
the heavy load concentrated on a single point may reach the strength capacity
 162 JENG ET AL.
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Figure 10 Moment/force indices under various boom angles for the mobile crane with six supporting
points.

of an outrigger under loading, the working radius is limited. Figure 12(a) shows
the resultant working radius decreases as lifted load increases. The outrigger span
enlarges the safe working area, which changes based on the rotation angle of the
crane at two side regions (Fig. 12(b)). As the outrigger extension increases, the safe
working area increases.

SAFETY MONITORING SYSTEM

According to Fig. 13, a prototype device consisting of a main controller and
four sensor modules is implemented to demonstrate the feasibility of the proposal
 OUTRIGGER FORCE MEASURE FOR MOBILE CRANE SAFETY 163
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Figure 11 Moment/force indices under various lateral distances of outriggers for the mobile crane with
six supporting points.

scheme in terms of automatically monitoring the online safety of a truck-mounted

crane. Consisting of a strain gauge transducer, a length encoder, an inclinometer,
and a shaft angle resolver with flexible brackets on laterals sides of the crane boom,
the crane condition sensors provide electric signals pertaining to lifted load, boom
length, boom angle, and rotational angle of the crane. A RS485 serial interface
that utilizes differential and twisting signals is embedded in the sensor module.
Each module located near the corresponding sensor element transports acquisition
data and status events to the main controller via the industrial standard Modus
 164 JENG ET AL.
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Figure 12 Safe working areas of the mobile crane with six supporting points.

RTU protocol. Simple and inexpensive to construct, the remote sensor modules are
adjustable within a wide range to adhere a variety of mobile conditions.
A general purpose 8051 microcontroller is embedded in the main controller.
The main controller communicates with the multiple remote sensor modules on
the RS485 network. The microcontroller unit (MCU) takes user input from a six-
button keypad and displays the results on a four-digit seven-segment light-emitting
diode (LED) display. The main controller can provide real-time information on
the lifted load, boom angle, boom length, rotation angle, and effective use of the
outrigger. The solution adopted in the proposed scheme incorporates the real-time
 OUTRIGGER FORCE MEASURE FOR MOBILE CRANE SAFETY 165
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Figure 13 Antiupset monitoring system.

acquisition data pertaining to the working configuration, subsequently yielding two

stability indices to ensure safe crane operations. The output signals operate visual
display devices that either inform the crane operator of safe operating limits or
automatically suppress certain crane functions, e.g., swinging and lifting within safe
limits. The monitoring system comprises an integrated, real-time system capable of
continuously monitoring, analyzing and evaluating acoustic alarm events.

COMPARISONS OF OVERTURNING MEASURES

Different measures can be applied to quantify overturning stability. A
comparison of overturning moment with the stabilizing moment is a traditional
measure (Queensland Government homepage, n.d.) based on which crane stability
is defined as follows:

Moverturn
Stradition =  (16)
Mstablize
 166 JENG ET AL.
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Figure 14 Comparisons between Smoment and Stradition . Note that blue lines indicate Smoment given in
this study. Red lines indicate Stradition (Queensland Government homepage, n.d.).

Substituting the Eqs. (11)–(14) into (16) and replacing symbol Fload /Floadtip with
Smoment yields

Fload · dload + ni=1 Fpbi · dpbi
Stradition = F ·d   (17)
load load
S
+ ni=1 Fpbi · dpbi
moment

These two indices, Stradition and Smoment , which are monotonic increasing functions,
always increase as Fload increases, and are all suitable for quantifying overturning
stability. Two stability indices exceeding 100% indicates that the sum of overturning
moments exceeds the sum of stabilizing moments. Figure 14 shows these two indices
under the same operational configuration as that in Fig. 5. The benefit of the
conventional index Stradition is that it does not consider outrigger forces. A drawback
is that the precise position of the overturning edge must be predetermined. As the
gravitational center of a mobile crane does not coincide with the rotational center,
determining the actual position of overturning edges is difficult. From the viewpoint
of safe operation, Smoment , defined as the ratio of current lifted load to tipping load
Floadtip becomes easier to recognize intuitively the safety margin than the traditional
index Stradition .

CONCLUSIONS
A mobile crane capable of lifting a predetermined load is typically equipped
with an outrigger unit that comes into contact with the ground to increase lift
capacity. The hosting system becomes an underdetermined system when only the
static equilibrium is considered. For a crane with multiple stabilizer legs, the
upper/lower bounds of outrigger forces can be obtained via two-phase simplex
 OUTRIGGER FORCE MEASURE FOR MOBILE CRANE SAFETY 167

algorithm. When four outriggers support a mobile crane, the minimum/maximum

pruning operation that attempts to restrict the two bounds until design variables
fulfill a set of inequality constraints is available to increase the computational
efficiency of evaluating the allowable reaction forces of outriggers.
The moment index quantifies the tendency of tip-over behavior of a mobile
crane; the force index ensures that outriggers do not fall through the pavement,
sink into soft ground, or collapse. These two indices can be expressed as a function
of a chassis rotational angle, boom angle, boom length, and outrigger length.
Notably, simultaneously increasing the boom angle and decreasing the boom length
increases stability. Additionally, outriggers decrease the overturning moment by
simply moving the reference point in close proximity to the load. Lift capacities are
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adjusted based on boom position, in which the left/right and front/rear sides of the
mobile crane are differentiated.
Importantly, this work contributes to efforts to improve stability measure.
Although capable of easily determining crane stability under operating
configurations, the conventional relationship between stabilizing and overturning
moments does not consider outrigger reaction forces. Determining the outrigger
forces is an effective means of accurately predicting the risk of overturning for
a mobile crane, ultimately protecting a crane against support failure. A real-time
antiupset device that monitors these two indices warns the crane operator via a
signal if the load moment upsets the crane or the failure risk of the supporting
surface is approached or exceeded. A practical safe working area that reflects an
actual situation closely resembles the configuration of outrigger supports with
cutting corners.
As is well known, a static finite element (FE) can assess precisely overturning
stability due to deformation of either the crane or the outriggers that may lead to an
extremely different nature of the overturning stability. Mobile crane manufacturers
must analyze the shape and dimension of the mechanical parts during the design
phase. However, the scheme adopted in this study is more appropriate for a
microprocessor-based antiupset device that involves real-time monitoring of crane
stability.

NOMENCLATURE
Fweight gravitational force of upper mobile crane
Fpbj gravitational force of section j of the telescopic boom
Feqx , Feqy , Feqz three components of equilibrium force
Meqx , Meqy , Meqz three components of equilibrium moment
Rjx  Rjy  Rjz three components of reaction force of outrigger j
Rjmax upper bound of reaction force of outrigger j
Rjmin lower bound of reaction force of outrigger j
Rcrit maximum reaction force of outrigger
Fload lifted load
Floadtip tipping load

xweight  yweight  gravitational center of upper mobile crane

xpbj  ypbj  gravitational center of section j of the telescopic boom

xRj  yRj  center point of outrigger j
 168 JENG ET AL.

xload  yload  center point of lifted load

 rotation angle of the chassis
 boom angle
Smoment moment index
Sforce force index
Mstablize stabilized moment
Moverturn overturning moment

APPENDIX
The following steps summarize the procedure and corresponding rationale
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for determining the overturning stability of a mobile crane equipped with four
outriggers.
Step 1: Initial feasible range of the outrigger force R4z

R4max =  and R4min = 0

Step 2: Obtain the new feasible range of the outrigger force R4z from
equations in (9) and (10).
For i = 1 2 3
If i4 /R1 R2 R3 > 0 then
 
Q
R4max = min R4max  i
i4

Else
 
Q
R4min = max R4min  i
i4

End if
End for-loop
Step 3: An infeasible constraint implies an unstable crane; otherwise, the
smaller and largest allowable values can be derived for each outrigger force using
equation in (7).
If R4max < R4min then

Print “the mobile crane is unstable”

Else
For i = 1 2 3
If i4 /R1 R2 R3 > 0 then

Qi − R4min · i4
Rimax = and
R1 R2 R3
Qi − R4max · i4
Rimin =
R1 R2 R3
 OUTRIGGER FORCE MEASURE FOR MOBILE CRANE SAFETY 169

Else
Qi − R4max · i4
Rimax = and
R1 R2 R3
Qi − R4min · i4
Rimin =
R1 R2 R3

End if
End for-loop
End if
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ACKNOWLEDGMENTS
The authors would like to thank the Division of Occupational Safety, Institute
of Occupational Safety and Health, Council of Labor Affairs of the Republic
of China, Taiwan, for financially supporting this research under Contract No.
IOSH89-S131.

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