Simulating Mobile Machinery

The development of construction machinery with SimulationX allows for early analyses in the design process and spares us expensive prototypes.

Thomas Esche, Liebherr-Werk Bischofshofen GmbH

Mobile machinery – reliable, economical, comfortable, energy efficient

Be it construction machinery, agricultural machinery, forestry equipment or municipal vehicles – manufacturers of mobile machinery must develop their products in a way that such machines can cope with challenging environments throughout alternating work cycles – and often enough there are no predevelopment resources available. With a powerful package comprising our simulation software, engineering expertise and a broad network of industrial partners and research experts, your product development runs economically and sustainably right from the very start. ESI ITI’s engineers support you throughout the entire development process of mobile machinery.

Market Requirements

Developing innovative mobile machinery (construction and agricultural machinery)

In order to meet the rising performance requirements of their customers, manufacturers need to find the optimum balance in the interaction between man and machinery for each work cycle. Stricter environmental as well as health and safety regulations, especially tighter exhaust gas limits for industrial engines (Stage/Tier IV) call for new, less consuming concepts without impacting performance in a negative way. This has enormous consequences for the entire layout of increasingly complex machines. Recuperation, light-weighted design and alternative drive systems are the most promising solution approaches in the current development of mobile machinery. Take advantage of cutting-edge multiphysics simulation tools to push and realize your ideas within economical boundaries.

Requirements for manufacturers:

  • Counter time and cost pressure in product development effectively also with small development teams
  • Understand and master the growing complexity of heavy machinery as well as the requirements of an increased use of mechatronics
  • Integrate development and testing of a growing number of control units early in the design process
  • Handle a broad diversity of variants efficiently
  • Integrate varying components from suppliers fast and safely
  • Prove and ensure reliability, availability, maintainability and safety
  • Support processes for division of labor – between suppliers and OEMs as well as between different branches or departments of the same company
  • Ensure compliance with legal requirements and standards already during the development
  • Prevent warranty issues up front

Requirements for operators:

  • Maintain a high quality level in meeting increased performance and environmental requirements
  • Integrate mobile machinery in homogenously linked work processes (e.g. road construction)
  • Comply with environmental as well as health and safety standards (energy efficiency, vibrational comfort, noise, dirt and exhaust gas emissions)
  • Increase ease of use and comfort
  • Reduce costs and time for installation and erection procedures of cranes, for example
  • Ensure maximum availability of the machinery and keep maintenance costs at a minimum
  • Train personnel free of risk with realistic training simulators

How much energy is little energy?

How much energy does it take to move mountains? How can we bring the vision of a green wheel loader to life? As a longstanding partner of leading car makers around the world, we know the ins and outs of innovative development topics, such as optimized combustion engines, hybridization, fast moving electric motors and all kinds of control units. Benefit from our experience. Let us apply together state-of-the-art development methods to your mobile machinery and your product development environment. Make an appointment for a personal consultation straightaway.

Our Offer

Simulation solution for the development of mobile machinery

With such a vast amount of requirements, accurate analyses of transient, nonlinear processes are becoming increasingly vital. For such considerations, it is usually not sufficient to only look at stress analyses, flow calculations or cinematic simulations. Mobile machines like excavators, wheel loaders, agricultural and forestry machinery, road construction equipment, concrete mixers, concrete pump systems, cranes and hoisting gear, compression and tunnel boring machinery are mechatronic systems. Besides mechanical parts, they consist of hydraulic actuator systems and the corresponding control units. Many undesirable effects during operations later on have their cause in a poor interaction of the sub-systems from various physical domains. Especially the great number of nonlinear processes in mobile machinery is hardly manageable through measurements alone any longer.

That is why leading OEMs and suppliers around the world have been working with one of the leading simulations tool – SimulationX – and ESI ITI’s engineering services in their product development for years.

SimulationX – software for the development of mobile machinery

  • Multiphysics simulation in the development of complex machinery
  • Modeling and simulation of individual components and entire drivelines
  • Analyzing and comparing conventional (with combustion engine), electric and hybrid drive systems
  • Optimization of hydrostatic drive and steering systems for mobile machinery
  • Development and optimization of controller components with respect to functional and energetic aspects early in the design phase
  • Calculation of forces and moments acting on winches and pulleys of hoist and suspension ropes with respect to rope properties (e.g. length, mass, tensile strength) and load profiles
  • Compliance with certification related safety requirements (e.g. stability)
  • Identification of optimization potential in line with EN 13000 and EN 13001 for designing cranes
  • Utilization of training simulators with physically correct model behavior of the machine

Manufacturers of cranes, listen up!

Dimension your hoist and slewing mechanisms as well as your drive components and controllers, while staying in control of dynamic effects right from the start. Prove your crane’s stability for various load cases and movements at the click of a button. Calculate dynamic loads fast and safely for deceleration procedures, emergency shutdown, disastrous situations or ground contact. With ESI ITI’s simulation solutions, you master all physical interactions in mobile machinery. The software is suitable for beginners and experts alike. Read on to find out which version may be best suited for you.

more about SimulationX

Fast response to market demands and short development cycles with simulation-based controller development

Innovative and efficient drive and work systems combine a large number of different technical domains. The share of software-controlled processes and functionalities is constantly growing also due to advances in autonomous driving. To master such complex systems and maintain efficient development processes, methods of virtual prototyping, i.e. system analysis with simulation-based system models, have become common practice. Especially controllers can be developed fast and reliably with the help of a model, while technical concepts and safe operation can be tested and proven.

Use case Palfinger

Engineering services in the development of mobile machinery

Safeguard functionality and energy efficiency for your concept without expensive and time-consuming revisions later on. ESI ITI’s engineers know the ropes and are there to help you!


Head over to the customer center

… and discover the possibilities: download the SimulationX trial version for free, find learning material and user reports and book your next training. Register now and get started.

customer center

Customers and references

All over the world, suppliers in the construction machine industry, use SimulationX for designing and optimizing mobile machines, e. g. ABB, Bosch Rexroth, CNH, ETO Magnetic, Hawe Hydraulik, Hitachi, Komatsu, Liebherr or Putzmeister.

  • Liebherr

    SimulationX enables Liebherr in Bischofshofen to optimize operator comfort and vehicle dynamics of wheel loaders

    about Liebherr's project
  • Palfinger

    PALFINGER uses SimulationX for the development of elevated work platforms – from the design phase to software tests.

    Use case Palfinger
  • Liebherr

    Liebherr-Werk Ehingen GmbH uses SimulationX during the pre-development of mobile cranes and crawler cranes

    about Liebherr's project
  • Putzmeister

    Putzmeister uses SimulationX for the design of the highpressure concrete pumps that build Dubais‘ Skyscrapers

    about Putzmeister's project
  • TU Chemnitz

    Interpretation of a yarder’s mechanisms including the carraige was carried out using the simulation software SimulationX.

    about TU Chemnitz' project
  • Management Center Innsbruck

    Vehicle Dynamics of a Telescopic Handler

    about MCI' project
  • HVAC technology in vehicles, machinery and buildings

    Application examples and solutions

    Go to HVAC technology
    Jörg Arloth Sales
    Dr. René Noack Engineering
    Florian Ohser Engineering
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