Real-Time High-Fidelity Simulation of Electro-Hydraulic Driven Mobile Machines

Abstract

This work presents a high-fidelity, real-time simulation framework for electro-hydraulic mobile machines, featuring, which is exemplified by case study of a Patu 655 crane system powered by a brushless servo motor. A detailed dynamic model of the hydraulic subsystem is developed in MATLAB, capturing key aspects such as fluid dynamics, actuator behavior, and mechanical linkages. This model creates a realistic simulation environment suitable for control prototyping and human-in-loop applications. In Simulink, classical Proportional–Integral–Derivative based control architecture is employed to regulate the servo motor and hydraulic environment actuation system of the crane model. The controller is tuned to ensure accurate position tracking, stable pressure regulation, and efficient energy use under fixed load conditions. The precision of the servo motor enhances the system’s responsiveness, allowing fine-grained control over motion and force transmission. To enable real-time implementation, an artificial intelligence-based reduced-order model was developed in MATLAB/Simulink. This approach reduces the computational complexity of the full-order high-fidelity model while retaining its dynamic behavior. The approach enables reliable real-time operation and efficient integration of adaptive electro-hydraulic systems in industrial machinery.