Numerical simulation of operations of hydraulic excavators for polydisperse bulk materials and different configurated buckets

Excavators have been used in construction for a century, and simulation-based performance prediction is cost-effective for equipment design. In practice, particle size varies, and it is of interest to investigate how excavators perform differently when handling polydisperse bulk materials using different configurated buckets. This work simulates three ternary-sized material stockpiles and evaluates the performance of excavators with different bucket configurations (including width, depth, and number of tooth stations) on the basis of co-simulation of multibody dynamics and discrete element method. The results show how excavator performance indicators such as bucket payload and hydraulic power consumption relate to particle size distribution and bucket configuration. This work demonstrates the usefulness and potential of co-simulation in optimising equipment design and operation. Further research directions should be focused on the prediction of excavator performance and bucket wear in more complex working environments and the improvement of operating strategies.