Simulation and validation of hydraulic track drive systems for electrification of heavy-duty machinery

Abstract

Abstract This work explores the challenges and necessity of replacing inefficient hydraulic systems in large-scale heavy-duty off-road machinery, such as mobile rock crushers, with innovative electric solutions. A mathematical and Simulink simulation model of a rock crusher’s hydraulic track drive is developed and validated against physical test data. The model investigates the power developed by the hydraulic system during operation via simulation and is validated using results obtained from physical testing of the machine. These findings can inform the specification of an equivalent electric system, enabling similar torque delivery without the idle energy losses typical of fossil fuel systems. The simulation also supports appropriate energy storage sizing to perform required manoeuvres. The simulated system accuracy ranges from 4 to 12%, with a 20% outlier attributed to real-world inefficiencies like fluid losses and transient response delays. This level of accuracy is considered sufficient for guiding electrification efforts, ensuring the proposed electric system is neither under- nor over-designed. The insights gained from this simulation work contribute to the transition of heavy-duty machinery from hydraulic to electric powertrains, supporting the development of more energy-efficient and sustainable solutions.