DTE AICCOMAS 2025

Developing a Calibrated Physics Based Digital Twin for Construction Vehicles

  • Karanfil, Deniz (University of California Davis)
  • Lindmark, Daniel (Algoryx Simulation)
  • Servin, Martin (Umeå University)
  • Torick, David (University of California Davis)
  • Ravani, Bahram (TSR Corporation)

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This paper presents the developments of a calibrated digital twin of a wheel loader as an example of a heavy vehicle used in construction. In the system developed, the virtual twin of the physical wheel loader uses a physics based multibody dynamic model in the software Algoryx Dynamics [1]. Interactions of the wheel loader’s bucket while in use in construction can be simulated in the virtual model generating data on force and hydraulic pressures encountered by the lifting mechanism of the wheel loader. The trustworthiness of the simulation results generated is always a question unless the system can be calibrated by experimentation on the physical twin of the system. In this work, a physical wheel-loader was instrumented with several sensors and was used in experiments interacting with the construction environment. The sensor data was then used to determine bucket forces and hydraulic cylinder pressures and compared to the simulation data using the virtual twin. This allowed for calibrating the virtual models to provide accurate representation of the physical interaction of the device with the construction tasks. After the digital twin calibration, the simulation was able to estimate the magnitude of the forces on the bucket base with only 5 to 10% average error depending on the stage of the wheel loader operation. The results presented enhance the state of knowledge in the field of digital twin technologies in better integrating the virtual and the physical twins as well as indicating a promising application of this technology for construction equipment. REFERENCES [1] M. Servin., T. Berglund., and S. Nystedt. A multiscale model of terrain dynamics for real-time earthmoving simulation. Advanced Modeling and Simulation in Engineering Sciences 8, 11 (2021).