Specialized Simulation Software for Complex Excavator Kinematics and Mechanical Linkage Systems
Advanced Engineering Software Based on Multibody Simulation
DIGertis is a specialized software solution developed by simertis for modeling, simulation and systematic analysis of hydraulic excavator attachments and other complex mechanical linkage systems.
DIGertis was developed as an application-specific plug-in for MSC Adams. Similar in concept to specialized Adams modules such as Adams/Car, DIGertis utilizes the powerful modeling, simulation and solver capabilities of the existing multibody simulation environment and extends them with industry-specific functionality.
These extensions include a dedicated user interface tailored to excavator engineering, automated generation of parametric simulation models, specialized calculation procedures and largely automated evaluation of simulation results.
<br/>A key objective was to make advanced simulation methods accessible to engineers and designers without requiring specialized knowledge of multibody simulation.
DIGertis enables the analysis of working envelopes, digging forces, lifting capacities and machine stability for different excavator configurations. Automated modeling, simulation and post-processing significantly reduce the effort associated with recurring engineering tasks and provide a sound basis for design optimization.
Analysis of Different Excavator Kinematics
The performance of a hydraulic excavator is strongly influenced by the kinematic configuration of its attachment.
Different linkage and lever arrangements determine the available working envelope, digging forces, lifting capacity and overall operating characteristics of the machine.
DIGertis was developed to investigate various kinematic concepts, including:<br/><br/><br/>
- Conventional backhoe and face-shovel configurations
- Parallel kinematics
- TriPower kinematics
- Other complex mechanical linkage systems
Using a general numerical approach based on multibody simulation, different kinematic configurations can be investigated within a common simulation environment.
Rather than developing separate analytical calculation methods for each linkage concept, DIGertis makes systematic use of the capabilities of an established multibody simulation system.
This enables consistent design comparisons and targeted optimization of geometry, force transmission and working range.<br/><br/>
Parametric Modeling and Automated Model Generation
One of the key features of DIGertis is its largely automated model generation process.
Dedicated input interfaces allow engineers to define geometric parameters, masses, inertias, hydraulic characteristics and other relevant boundary conditions.
Based on these inputs, DIGertis automatically generates the corresponding multibody simulation model in MSC Adams.
Predefined model templates support different excavator configurations. Complex, geometrically coupled linkage systems can also be modeled using suitable numerical procedures.
This considerably simplifies the modeling of demanding mechanical systems.
Engineers can focus on their actual design tasks while complex model generation and numerical calculations are performed in the background.<br/><br/><br/><br/><br/><br/>
Calculation of Digging Forces, Lifting Capacities and Machine Stability
DIGertis enables systematic calculation of important performance characteristics throughout the complete working envelope.
The analysis capabilities include:<br/><br/>
- Breakout forces, tear forces and crowd forces
- Hydraulic and mechanical lifting capacities
- Machine stability and tipping limits
- Joint and bearing forces
- Hydraulic and geometric operating limits
- Influence of design modifications on machine performance
The calculations consider the relevant hydraulic, geometric and mechanical boundary conditions of the system.
As a result, DIGertis not only determines the available forces but also identifies the conditions limiting performance at a particular operating position.
This information supports targeted optimization of attachment kinematics and hydraulic system design.<br/><br/>
Extended Capabilities Through Dynamic Simulation
Unlike purely static calculation methods, DIGertis is based on a multibody simulation model.
The digging forces determined throughout the working envelope can subsequently be used as a basis for further dynamic simulations.
This enables additional investigations, including dynamic joint loads, forces acting on attachment components and machine behavior under critical operating conditions.
Combining kinematic analysis, force calculation and dynamic simulation provides capabilities beyond those of conventional calculation methods.
Automated Evaluation and Standardized Engineering Analyses
DIGertis includes dedicated post-processing functions for the automated evaluation of extensive simulation results.
Characteristic curves, performance diagrams and structured reports support the assessment of different designs and operating conditions.
A particularly important feature is the identification and visualization of performance-limiting boundary conditions.
Engineers can therefore determine not only the performance achieved by a machine but also which parameters need to be modified to improve it.
Standardized analysis procedures enable consistent, reproducible comparisons between different design variants.
Developed in Close Cooperation with Design Engineers<br/><br/><br/><br/><br/><br/><br/><br/><br/><br/><br/>
DIGertis was developed by simertis in close cooperation with engineers and designers working for the manufacturer of large mining hydraulic excavators in Dortmund, Germany.
The development took place within the former Terex mining excavator business, which subsequently became part of Bucyrus and later Caterpillar.
The participating engineers and designers specified the functional requirements, calculation procedures and desired analysis results. These requirements were derived directly from practical engineering tasks and established design workflows.
simertis was responsible for developing and implementing the modeling procedures, numerical methods, automation functions and integration into MSC Adams.
An essential consideration was that the intended users did not have specialized expertise in multibody simulation.
The software was therefore designed to enable advanced simulation analyses through application-specific user interfaces and largely automated calculation procedures.
The result was an engineering tool combining the practical requirements of design engineers with the numerical and methodological expertise of simertis.<br/><br/><br/><br/><br/><br/>
In addition to the original customer, DIGertis was also used by another engineering company providing development services for large mining excavators.
Scientific Validation and Industrial Application
The underlying numerical methodology was validated against established analytical calculation procedures.
For the investigated excavator configurations, the calculated digging forces showed excellent agreement with the analytical reference results.
The documented deviations were below 0.012% for the investigated cases.
The development of DIGertis was presented and documented at international scientific conferences.
Its industrial application and scientific validation demonstrate how established multibody simulation environments can be transformed into powerful, application-specific engineering tools through specialized extensions.
Scientific Publications
The development and methodology of DIGertis were presented in the following publications:
2009 – Thematic Conference on Multibody Dynamics
A MBS Solution to Analyze Attachment Kinematics of Hydraulic Excavators and Other Linkages
H. Haut, M. Dietrich, K. Nienhaus
2011 – 35th APCOM Symposium, Wollongong, Australia
In addition to the original customer, DIGertis was also used by another engineering company providing development services for large mining excavators.
Scientific Validation and Industrial Application
The underlying numerical methodology was validated against established analytical calculation procedures.
For the investigated excavator configurations, the calculated digging forces showed excellent agreement with the analytical reference results.
The documented deviations were below 0.012% for the investigated cases.
The development of DIGertis was presented and documented at international scientific conferences.
Its industrial application and scientific validation demonstrate how established multibody simulation environments can be transformed into powerful, application-specific engineering tools through specialized extensions.
Scientific Publications
The development and methodology of DIGertis were presented in the following publications:<br/>2009 – Thematic Conference on Multibody Dynamics<br/>A MBS Solution to Analyze Attachment Kinematics of Hydraulic Excavators and Other Linkages<br/>H. Haut, M. Dietrich, K. Nienhaus<br/>2011 – 35th APCOM Symposium, Wollongong, Australia<br/>A Multibody Simulation Solution to Analyse Attachment Kinematics of Hydraulic Excavators and Other Linkages<br/>H. Haut, M. Dietrich<br/>Both publications describe the modeling procedures, numerical methodology, automated analysis capabilities and validation of the software.<br/>DIGertis Today – Opportunities for Future Applications<br/>DIGertis was originally developed for earlier versions of MSC Adams and is currently not offered as a standard commercial software product.<br/>However, its underlying methods and software concepts may provide a valuable foundation for future applications.<br/>In response to specific customer inquiries, simertis can evaluate the technical feasibility of modernizing DIGertis for current Adams versions or developing a comparable application-specific solution.<br/>The experience gained from DIGertis continues to contribute to simertis’ expertise in extending advanced simulation environments with specialized numerical methods and automated engineering workflows for industrial applications.<br/>Interested in DIGertis or Similar Engineering Solutions?<br/>Would you like to learn more about DIGertis, or are you looking for a specialized solution for kinematic analysis and performance evaluation of complex mechanical systems?<br/><br/><br/><br/><br/><br/><br/><br/><br/>
In addition to the original customer, DIGertis was also used by another engineering company providing development services for large mining excavators.
Scientific Validation and Industrial Application
The underlying numerical methodology was validated against established analytical calculation procedures.
For the investigated excavator configurations, the calculated digging forces showed excellent agreement with the analytical reference results.
The documented deviations were below 0.012% for the investigated cases.
The development of DIGertis was presented and documented at international scientific conferences.
Its industrial application and scientific validation demonstrate how established multibody simulation environments can be transformed into powerful, application-specific engineering tools through specialized extensions.
Scientific Publications
The development and methodology of DIGertis were presented in the following publications:
2009 – Thematic Conference on Multibody Dynamics
A MBS Solution to Analyze Attachment Kinematics of Hydraulic Excavators and Other Linkages
H. Haut, M. Dietrich, K. Nienhaus
2011 – 35th APCOM Symposium, Wollongong, Australia
A Multibody Simulation Solution to Analyse Attachment Kinematics of Hydraulic Excavators and Other Linkages
H. Haut, M. Dietrich
Both publications describe the modeling procedures, numerical methodology, automated analysis capabilities and validation of the software.
DIGertis Today – Opportunities for Future Applications
DIGertis was originally developed for earlier versions of MSC Adams and is currently not offered as a standard commercial software product.
However, its underlying methods and software concepts may provide a valuable foundation for future applications.
In response to specific customer inquiries, simertis can evaluate the technical feasibility of modernizing DIGertis for current Adams versions or developing a comparable application-specific solution.
The experience gained from DIGertis continues to contribute to simertis’ expertise in extending advanced simulation environments with specialized numerical methods and automated engineering workflows for industrial applications.
Interested in DIGertis or Similar Engineering Solutions?
Would you like to learn more about DIGertis, or are you looking for a specialized solution for kinematic analysis and performance evaluation of complex mechanical systems?
simertis supports companies in developing application-specific simulation solutions – from numerical methodology and automated model generation to systematic engineering analysis.
Contact us to discuss your requirements and explore potential technical solutions.
