Development of HILS system for the electric motor using coupling analysis with rigid body system and hydraulic system

A new concept of HILS(Hardware-In-the-Loop Simulation) system for an electric motor using the real-time coupling analysis with rigid body system and hydraulic system is presented in this paper. From the fuel consumption improvement point of view, the electric drive system is applied to the construction machinery for improving fuel efficiency and reducing pollution emissions. In the development of the electric drive system, it is important to evaluate the dynamic characteristics of the electric motor and control system, then HILS provides an approach for efficient development. This HILS system can act the actual load on the motor by calculating the coupling system equations of motion with the rigid body system and the hydraulic system in real-time. The real-time simulation was conducted by newly developed simulation model that the rigid bodies were actuated by the linear hydraulic actuator. A test rig was developed following this concept, in which the load computed by real-time simulation of the actual digging operation on the hydraulic excavator was exerted to the electric motor. The test results with developed testing system were compared with the simulation results using the simulation model with the electric motor. It is demonstrated that the HILS system of the electric motor can realize the actual digging operation of the hydraulic excavator.