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Mobile heavy article tilter and positioner (HATP) is special purpose vehicle designed to level, articulate and positioning of very heavy load within the accuracy of arc minutes and in a stipulated time in fully auto mode. HATP system uses sophisticated electronic controller system to carry out required task in auto mode. This electronic controller system comprises of various types of electronic hardware, software, sensors and actuators. As this system is dealing with heavy load, any failure in any of subsystem of HATP can result into catastrophe. Therefore active and passive safety measure at various levels must be incorporated into system which firstly prevents the failure and reduce the effect of failure. The safety system for HATP system has been divided in three major levels: 1. Access level safety 2. Operational safety 3. Preventive safety. All three levels of safety is incorporated at appropriate subsystem based on Risk Priority Number (RPN) and failure mode effect analysis.

Close loop motion control implementation for electro hydraulic system with multistage telescopic cylinder aimed to articulate heavy load to desired angle while keeping acceleration, velocity of load and time to reach the desired angle within acceptable limit possesses stringent control system strategies. Conventional PID (Proportional-Integral-Derivative) control algorithm cannot be applied directly to control the system as these algorithms are also required to meet various other criteria apart from just to stabilize the system around the set point. In case of fail to meet these criteria can cause the damage to the components of subjected system and lead to disaster in worst case scenario. This paper describes the model based design approach to implement smooth motion control for heavy duty systems.