Design of Control System for Hydraulic Lifting Platform

with Jack-Up Wind-Power Installation Vessel

Xuejin Yang, Dingfang Chen, Mingwang Dong, and Taotao Li
Research Institute of Intelligent Manufacture & Control,
Wuhan University of Technology, Hubei, China
{yangxuejin.2007,taotaoliwhut}@163.com, cadcs@126.com

Abstract. Jack-up wind-power installation vessel is the most important tool in

construction of wind farm. And the control system for hydraulic lifting platform
is the key point of jack-up wind-power installation vessel. Therefore the design
of the control system for hydraulic lifting platform with jack-up wind-power installation vessel is a basic and formidable problem. This article provides an integrated solution to the design of control system. Firstly, on the base of actual
working condition, we introduce the control principle and basic requirements of
the hydraulic lifting platform, such as the structure of leg, vessel gradient,
alarm, calibration. Secondly we introduce the design solution of PLC (Programmable Logic Controller) control system, which includes the design solution of hardware as well as software for the hydraulic control system. In this
part, we introduce the basic components and main function of hydraulic control
system, hardware scheme, software design project. Then we introduce a good
human-machine interface. Finally we do the work of program design according
to the process of lifting unit. By using wincc-flexible and PLCSIM, we can
layout the control module well and realize the man-machine interaction. At last,
we can obtain a viable hydraulic control system and verify feasibility of the hydraulic control system by simulation software. At the same time, we obtain the
working parameters of the lifting unit from the simulation.
Keywords: hydraulic control, Programmable Logic Controller, wind-power,
hydraulic lifting platform.

Introduction

As renewable energy, wind energy is attracting more and more attention. With the
development of science and technology, increasing wind farms are under building. As
the main component of wind farm, offshore turbine is very huge and hard to be installed. So we should use an important tool-- jack-up wind-power installation vessel
to finish the installation. As an important component of jack-up wind-power installation vessel, the control system of hydraulic lifting platform is a guarantee for the
normal work of it. For the vessel is very huge, we must guarantee the precision and
stability of hydraulic lifting platform. PLC control system is widely used because of
its high precision and good stability. So in this article, we design a PLC control system of hydraulic lifting platform based on modular design.
Q. Zu, B. Hu, and A. Eli (Eds.): ICPCA-SWS 2012, LNCS 7719, pp. 711718, 2013.
Springer-Verlag Berlin Heidelberg 2013

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The Control Principle of Hydraulic Lifting Platform

The Jack-up wind-power installation vessel includes four legs, and each leg contains
two groups of hydraulic cylinders. The first group of hydraulic cylinders is known as
the secondary cylinders, another group is called the primary cylinders. Threedimensional model of lifting unit for the Jack-up wind-power installation vessel is
shown in Figure 1.

Fig. 1. Lifting unit of one leg

Fig. 2. Process of one stroke for the lifting unit

Figure 2 shows the process of one stroke: secondary pin is pulled out, then the secondary cylinders rise up; then secondary pin is pulled back and primary pin is pulled
out, finally primary cylinders rise up, then primary pin is pulled back. And the lifting
process of hydraulic lifting platform can be divided into four parts: leg lifting, leg
lowering, platform lifting, platform lowering. In this article, we only introduce the
process of leg lowering.

The Design Process of Hydraulic Lifting Platform

3.1

The Basic Requirements and Components of the Hydraulic Control

System

Based on the actual working condition, the hydraulic control system must meet the
following requirements:
(1) Function of vessel gradient display and its alarm.
(2) Function of status display for lifting device and its alarm.
(3) Function of display for hydraulic system parameters in real time and its alarm.
In Figure 3, the hydraulic control system includes central console and local control
center. The central console can realize the function of overall control for the system.
Local control center can communicate with the central console, which is equipped
with a local control cabinet. In the condition of legs individual operation, the local
control center works by the central/local switch.

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The layout of hardware for the PLC control system includes three parts: central
console, local console, and actuator. And each part also contains many elements.
Central console: it includes IPC (industrial personal computer) and main PLC.IPC
is used for controlling the whole action of the hydraulic lifting platform. At the same
time, it is connected with the main PLC by MPI communication.
Local console: local console is laid near the leg, whose main function is to control
the lifting of leg separately. Here we choose the distributed I/O site-ET200M, which
is used in the condition that the number of the remote sites I/O points is huge.
Meanwhile, we should provide the power for ET200M.
Actuator: this part includes motor, hydraulic pump, solenoid valve, and sensor.
Some are used to provide status information, and some are used to realize the action
or provide the power.
local
console
1
local
consol
e2

local
consol
console
e4
local
console
3
central

Fig. 3. Layout of hardware for the PLC control

3.2

Structure Design of Software

Through the design of the software program, the hydraulic control system can complete the intended action with the input signal. We use the thought of modular design.
And the master control program can be divided into four modules, as in Figure 4.

Fig. 4. Design of software for hydraulic control system

The monitoring module for hydraulic system status: its main function is to monitor
the working status of the hydraulic system in real time, including hydraulic system
pressure, oil level, oil temperature and oil cooling system. Pressure screen displays
the pressure values of hydraulic cylinders. And oil level is divided into three levels:

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high, low, the lower. Oil temperature is shown directly on the screen in numerical
form. The status of the cooling system is also displayed on the screen.
The monitoring module for vessel: this module's main function is to monitor the
working status of vessel's components in real time, including legs height, legs load,
lifting speed of hydraulic cylinders and vessels gradient.
The Monitoring module for hydraulic components: this module includes the location of lifting cylinder, pins status and pumps valve. The screen shows the outstretched distance of 32 lifting cylinders, 8 secondary pin cylinders and 8 primary pin
cylinders. Meanwhile, the screen displays the pumps valves.
Alarm module: it includes main general alarm, HPU alarm, LCC alarm, legs
alarm.
3.3

Program Design

For leg lowering, the whole working process can be divided into 6 phases in figure 5.
2535
2500
secondary pin
2385
in

0.5
0.5
0.5

2285
secondary
cyliner lifting

1.4

0.5

Primary pin
(out)

2500
2485

Primary cyliner
lifting

2.0

215
0.5
115

secondary pin
(out)

35
0
-35

0.5
0.5

Distance Speed

0.5

Primary pin
in

0
-35

Speed Distance

Fig. 5. Working process of leg lowering

(1) Secondary pin pulling out

In this phase, secondary cylinder lifts at a speed of 0.5m/min. at the same time,
secondary pin is pulled out, and travel switch will limit the maximum distance of the
secondary pin.
(2) Secondary cylinder lifting
Here secondary cylinder lifts at a speed of 1.4m/min. when the distance of the cylinder reach the number of 2285mm, the sensor sends a signal and the speed decreases.
(3) Secondary pin putting in
When the speed of secondary cylinder becomes 0.5m/min, secondary pin is put in.
after engaging, the sensor sends the signal, and next phase starts.
(4) Primary pin pulling out

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In this phase, primary cylinder lifts at a speed of 0.5m/min. at the same time, primary pin is pulled out, and travel switch will limit the maximum distance of the secondary pin.
(5) Primary cylinder lifting
Primary cylinder lifts at a speed of 2.0m/min. when the distance of the cylinder
reaches 2485mm, the sensor sends a signal and the speed decreases.
(6) Primary pin putting in
When the speed of primary cylinder becomes 0.5m/min, primary pin is putted in.
After engaging, the sensor sends the signal. A stroke ends.
3.4

Synchronization Control of Cylinder

As the platform is sensitive to the gradient, we must guarantee the synchronization of

cylinder. Using the height difference as the feedback control signal, we can control
the height difference by adjusting the rotational speed of motor. And through this
method, we can realize the synchronization of cylinder. The control algorithm is
showed as follow.
When the cylinder lifts, we choose -. If the cylinder lowers, we choose +.
v
v

v
| |

(1)

b, c

| |

(2)

hheight difference
acontrol factor
bcontrol inflexion
v0set speed
vactual speed of cylinder
On the other hand, the flow rate of cylinder is related to the speed. And the formula is
show as follow.
Q

10

(3)

Qflow rate of cylinder

Athe effective action area of cylinder
v volumetric efficiency of hydraulic cylinder,
vlifting speed of cylinder
ddiameter of rod chamber
Ddiameter of non-rod chamber
3.5

Design for HMI

When the hydraulic lifting platform works, we should keep watching the working
status of the vessel. And HMI (human-machine interface) can provide us the convenience. So the design of HMI is an essential aspect for hydraulic control system.

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HMI can be divided into two parts: central console interface and local console
interface.
(1) The design of the central console interface
The central console interface is divided into four sections: basic startup information block, HPU control block, pin control block, display screen.
Basic startup information block includes switches (CCD switch, central/local
switch, and manual/semi B automatic switch) and buttons (leg lifting, platform lifting,
support model, pre-loaded, half-brake, speed change and fixed detachment). According to different needs, we can make appropriate choice.
HPU control block is used for HPU's control, including start and stop of HPU, status display of LCC, emergency stop.
Pin control block is used for the control of legs pins, including status display of
pin system, reset, and testing.
(2) The design of the local console interface
Local operation is adopted especially in the process of legs lifting. Local console
interface includes two parts: pressure display and buttons (local/central switch, leg
lifting, platform lifting, pre-loading, fixing, local control and alarm).

Fig. 6. Central control interface

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Simulation

When we complete the above design work, we will obtain a whole PLC control system of hydraulic lifting platform with jack-up wind-power installation vessel. Due to
the limitation of actual condition, we have to use the software to verify our design. In
this article, we choose the PLCSIM and wincc-flexible.

Fig. 7. Interface of simulation

In figure 6, we verify the correctness of the program. At the same time we know
the working status from the interface. We also can realize the switch of different
working module.
We can obtain the actual numerical valves of working pressure, and speed from the
control system. And the actual valves are shown in table 1.
Table 1. Actual working status of leg lifting

Secondary pin out

working pressure of system

(Mpa)
5.75

Flow rate of
the main line
(L/min)
328.74

Secondary cylinder lifting

5.75

647.76
328.74

1.4
0.5

Secondary pin engaging

5.75

328.74

0.5

Primary pin out

0.65

Primary cylinder lifting

0.65

Primary pin engaging

0.65

328.74
1004.84
251.2
251.2

0.5
2.0
0.5
0.5

action

Speed of cylinder(m/min)
0.5

Conclusion

Based on the actual analysis of working condition for hydraulic lifting platform, we
obtain the control principle of the hydraulic lifting system and the structure of lifting
unit. At the same time, we complete the design of control system for hydraulic lifting
platform according to the actual requirements, including the design of hardware and

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software for PLC control system, the design of good human-machine interface by
using wincc- flexible. By and large, this article completes the design of control system
of hydraulic lifting platform with jack-up wind-power installation vessel. Meanwhile
it can do well for the development of wind farm.
Acknowledgment. This research was supported by "the Fundamental Research Funds
for the Central Universities".

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