Research On Hardware In The Loop Simulation Platform For Hydraulic System Of Construction Machinery

As the advantages of high power density and speed rigidity, hydraulic systems were widely used in construction machinery. During hydraulic system designing period, the actual effect of design should be tested and verified by means of dynamic test on actual system and simulation test. On the basis of the completed hydraulic system test platform for dynamic performance, the hardware in loop simulation (HILS) platform was researched and developed. The simulation technology was brought into the hydraulic system test to reduce the cost of production of prototype, simultaneously, reduce manpower, resources and investment for the testing. Additionally, the simulation could be used for prediction and optimization before the test. Therefore, the HILS will bring important application value for hydraulic system design, analysis and improvement.This paper was based upon the project supported by the Science and Technology Bureau of Xiamen, which called"Development of Hardware in the Loop Simulation Platform for Dynamic Performance Testing of Hydraulic System on Construction Machinery", under grant number:3502Z20073017. This paper was focus on developing a set of HILS test platform for hydraulic system dynamic performance research, by updating a completed practical hydraulic system test platform in Xiamen XGMA Machinery Co., Ltd. The HILS test platform can be used to realize dynamic performance research of hydraulic system by computer simulation, also can be used for HILS test by introducing practical hydraulic system into simulation. In this paper, the research work carried out includes:Firstly, by analyzing the components and working principle of hydraulic system on platform, the hydraulic test platform was divided into several parts, and simulation model of each part was set up separately in MSC.EASY5, the whole hydraulic system model was then completed by connecting part models. Some tests were carried out to validate the performance of simulation. Interactive interface from hydraulic system simulation model in MSC.EASY5 to control system simulation model in MATLAB / Simulink was built, to achieve mutually data transmission between two models by code calling. Then the co-simulation was completed. The co-simulation supplied the hydraulic model an interface to practical system, it established a foundation for HILS, it also can be a good reference for further research of complicated control measure of hydraulic system. Secondly, a kind of soft real-time simulation control module was applied to figure out the problem of real-time in simulation, besides, simulation interface tool of LabVIEW was used to realize the important technique of network communication for real-time data transmission and the field system controlling. Eventually, the HILS system was completed set up.Finally, to verify the HILS system, tests in different conditions was designed and carried out, which was need in engineering. The test results showed that the HILS platform for hydraulic system of construction machinery can satisfy the need of actual engineering, and diversified HILS tests can be carried out on the platform, the error of results was small enough.The HILS platform for hydraulic system of construction machinery set up on this paper upgrade the level of research on construction machinery industry, and there is no similar applied production interiorly by far. The HILS platform have been tested by the cooperative company, all of the technique index satisfy the program requests, and the HILS platform has passed the checking which was carried out by the Science and Technology Bureau of Xiamen.