Simulation Method for Hydraulic Tensioning Systems in Tracked Vehicles Using Simulink–AMESim–RecurDyn

We developed a robust tri-platform co-simulation framework that integrates Simulink, AMESim, and RecurDyn to address the dynamic inconsistencies observed in traditional tensioning models for tracked vehicles. The proposed framework synchronizes nonlinear hydraulic dynamics, closed-loop control, and track–ground interactions within a unified time step, thereby ensuring causal consistency along the pressure–flow–force–displacement power chain. Five representative operating conditions—including steady tension tracking, random road excitation, steering/braking pulses, supply-pressure drops, and parameter perturbations—were analyzed. The results show that the tri-platform model reduces tracking error by up to 60%, shortens recovery time by 35%, and decreases energy consumption by 12–17% compared with dual-platform models. Both simulations and full-scale experiments confirm that strong cross-domain coupling enhances system stability, robustness, and energy consistency under variable supply pressure and parameter uncertainties. The framework provides a high-fidelity validation tool and a transferable modeling paradigm for electro-hydraulic actuation systems in tracked vehicles and other multi-domain machinery.