Smooth Obstacle-Avoidance Trajectory Planning for Cable Cranes During Concrete Hoisting in Arch Dam Construction

The cable crane is the core hoisting equipment for high arch dam construction, and its hoisting trajectory is critical for both operational efficiency and safety. However, current trajectory planning does not adequately consider the underactuated characteristics of the cable crane. For instance, sudden stops or abrupt changes in direction can easily induce large swings of the bucket, causing safety risks and equipment wear. To address this issue, this paper developed a trajectory planning model for obstacle avoidance with smooth transitions in cable crane hoisting for arch dams and solved the high-dimensional optimization problem using a path–velocity decoupling strategy. First, a shortest path with geometrical conciseness and free collision was generated based on an improved A* algorithm to reduce the frequency of directional changes. Next, for different hoisting scenarios, segmented S-curve and polynomial velocity functions were proposed to ensure smooth velocity transitions. Then, an orthogonal experimental design was employed to generate a cluster of candidate trajectories that meet kinematic constraints, from which the optimal trajectory was selected using a multi-objective evaluation function. The results demonstrate that the motion trajectory planned using the proposed method is notably smoother. Compared with the traditional trapezoidal velocity method, it reduces the maximum swing amplitude of the bucket by 40.78% at a modest time cost. In real-time obstacle avoidance scenarios, the approach outperforms emergency-stop strategies, reducing the bucket’s maximum swing amplitude by 30.48%. This work will provide a reference for engineers to optimize the trajectory of large lifting equipment in construction fields such as high arch dams and bridges.