Analysis, Dynamic Modeling, and Simulation of an Electric Earthmoving Vehicle

The electrification of construction and earthmoving machinery is a key step toward reducing emissions, noise and environmental impact in industrial applications. This thesis presents the development of a system-level simulation model of an electric Mini Track Loader (eMTL), a prototype vehicle developed by Sampierana-Eurocomach (CNH). The scope of the work is to create a model capable of reproducing vehicle’s dynamic behaviour and energy performance under realistic operating conditions. The model is implemented in MATLAB/Simulink using Simscape and integrates the main subsystems of the machine, including battery, electric traction, pump motor, hydraulic actuators, mechanical drivetrain and a simplified thermal network. Particular attention is given to the electrical subsystem, with detailed modelling of IPM motors through efficiency maps, torque-speed limits, regenerative operation and closed-loop torque control. A custom battery model is developed to estimate the state of charge and to manage continuous and overcurrent operating regimes. Experimental data acquired an eMTL prototype are used to tune and validate the model. Simulations are performed for traction and lifting, as well as for combined working cycles. The results show that the proposed model can effectively predict motor currents, temperatures, battery discharge and overall vehicle performance. The hydraulic subsystem reproduces oil flow, pressure, valve behaviour and actuator dynamics, while a mechanical model captures the vehicle’s kinematics, including track motion and interaction with the ground, and boom and bucket movement. The simulation framework is coupled with a 3D animation that provides real-time visualization of the vehicle’s motion during the simulated missions. Overall, the developed model represents an effective tool for virtual testing, system analysis and design optimization of electric earthmoving machinery, reducing reliance on physical prototyping.