To address the anti-swing issue of the payload in bridge cranes, Proportional–Integral–Derivative (PID) control is a commonly used method. However, parameter tuning of the PID controller relies on empirical knowledge and often leads to system overshoot. This paper proposes an Improved Sparrow Search Algorithm (ISSA) to optimize the gains of PID controllers, alleviating adverse effects on payload oscillation and trolley positioning during the operation of overhead cranes. First, tent map chaos mapping is introduced to initialize the sparrow population, enhancing the algorithm’s global search capability. Then, by integrating sine and cosine concepts along with nonlinear learning factors, the updating mechanism of discoverer positions is dynamically adjusted, expediting the solving process. Finally, the Lévy flight strategy is employed to update follower positions, thereby enhancing the algorithm’s local escape capability. Additionally, a fitness function containing overshoot penalties is proposed to address overshoot issues. Simulation results indicate that the overshoot rates of all algorithms remain less than 3%. Moreover, compared with the Sparrow Search Algorithm (SSA), Particle Swarm Optimization (PSO), Simulated Annealing (SA), and Whale optimization Algorithm (WOA), the optimized PID control system with the ISSA algorithm exhibits superior control performance and possesses certain robustness and adaptability.

Bridge crane control systems are complex, multivariable, and nonlinear. However, traditional fuzzy PID control methods rely heavily on expert experience for initial parameter tuning and lack adaptive adjustment for the fuzzy universe. To address these issues, we propose a variable universe fuzzy PID controller based on the improved sparrow search algorithm (ISSA-VUFPID). First, tent chaotic mapping is introduced to initialize the sparrow population, enhancing the algorithm’s global search capability. Second, the positioning strategy of the northern goshawk exploration phase is integrated to improve the search thoroughness of sparrow discoverers within the solution space and to accelerate the optimization process. Last, an adaptive t-distribution perturbation strategy is employed to adjust the positions of sparrow followers, enhancing the algorithm’s optimization ability in the early search phase and focusing on local exploitation in the later phase to improve solution accuracy. The improved algorithm is applied to tune the initial parameters of the PID controller. Additionally, system error and its rate of change are introduced as dynamic parameters into the scaling factor, which is used to achieve adaptive adjustment of the fuzzy universe, thereby enhancing the safety and reliability of the control system. Simulation results demonstrate that the proposed ISSA-VUFPID control method outperforms ISSA-FPID and ISSA-PID control methods. It reduces the trolley’s positioning time and minimizes the load’s maximum swing angle, demonstrating strong adaptability and robustness. This approach greatly enhances the robustness and safety of bridge crane operations.