Design and implementation of digital twin simulation system for hydraulic servomotor

• Published in: International journal of advanced manufacturing technology Vol. 138; no. 7; pp. 3415 - 3439
• Main Authors: Jiang, Zhanpeng, Tang, Jun, Sun, Yingbing, Liu, Zijian, Wu, Fenghe
• Format: Journal Article
• Language: English
• Published: London Springer London 01.06.2025; Springer Nature B.V
• Subjects: Accuracy; Advanced manufacturing technologies; CAE) and Design; Complexity; Computer-Aided Engineering (CAD; Data acquisition; Data processing; Design optimization; Digital twins; Efficiency; Engineering; Hydraulics; Industrial and Production Engineering; Industrial applications; Manufacturing; Mechanical Engineering; Media Management; Methods; Original Article; Real time; Servomotors; Simulation; Software; Turbines; Virtual modeling; System simulation; Hydraulic servomotor; Digital twin; Distributed real-time simulation
• ISSN: 0268-3768; 1433-3015
• DOI: 10.1007/s00170-025-15697-3

The increasing complexity and performance demands of hydraulic servomotors necessitate advanced simulation techniques for their design and optimization. In this study, a digital twin simulation system for hydraulic servomotors was developed, integrating an embedded data acquisition front-end with a distributed real-time simulation system. This system integrates real-time data acquisition with high-fidelity virtual modeling to provide an accurate and dynamic representation of the servomotor’s behavior. Leveraging this high-fidelity simulation capability within the distributed architecture enables the identification and analysis of potential operational issues, thereby improving the reliability and performance of the hydraulic servomotor. The implementation of this digital twin simulation system effectively reduces control system development time, mitigates development risks, and addresses the drawbacks of high testing costs and system complexity. Experimental results demonstrate the proposed system’s effectiveness in simulating various fault scenarios, indicating its potential for widespread adoption in industrial applications.