Development of an embedded simulation box to connect a real heavy machine with its simulation model

Abstract

The current research is based on the idea of Real-Time Simulation System, whereby there exists an ongoing interaction between the physical system present in reality and its simulated counterpart through the use of a simulation box. The objective of this thesis is to model, integrate, and validate such a system that bridges the gap between real-time acquisition of data from a physical mechanical system and its corresponding simulation model. For this, an embedded simulation box is created using C++ and run on a separate computer, enabling real-time one-way data reception from a MATLAB plant model to the embedded box. The framework facilitates engineers validating and testing observer performance, state estimation algorithms, and virtual sensing under realistic operating conditions. Within this paradigm, key modeling components such as multibody dynamics and state estimation through an Indirect Kalman filter are combined under a single real-time simulation framework. The embedded simulation box is defined by the nature of the component that has the task of performing calculations based on measurements, estimation of states, and prediction of unmeasurable quantities in order to achieve realistic simulations. The developed framework was validated by feeding noisy synthetic measurements from the MATLAB plant model into the embedded box, monitoring performance through state error estimation, and verifying real-time estimator response and cycle-time compliance. The work concludes with a discussion of the validation, responsiveness of the system, and future improvements.