Fast Data-Driven Modeling of Hydraulic Clutch Control Pressure with Latch-State Classification and Gaussian Process Regression
Authors: Yash Bagla, Jason Schneider
Organizations: Drive System Design Farmington Hills, Michigan, 48335
Abstract
This paper presents a data-driven method for modeling the pressure response of a hydraulic clutch control circuit. The system consists of a variable-force solenoid, accumulator, pressure regulator valve, and latch valve, and exhibits nonlinear behavior caused by hysteresis, latch transitions, and actuator dynamics. A baseline model using commanded current variables captured the general pressure response but failed to represent hysteresis and latch behavior accurately. The input vector was therefore extended with current derivative information, and several classifiers were tested to separate latch-related operating regimes before fitting Gaussian Process regression models to the resulting partitions. Nonlinear SVC and gradient boosting produced the highest latch-classification accuracy, and nonlinear SVC was selected for the final local-regression pipeline. The proposed approach was evaluated on unseen ramp-rate data and compared against a physics-based Amesim model. The machine-learning model reproduced the measured pressure response and hysteresis behavior more accurately than the physics-based simulation for the tested operating conditions. These results suggest that machine-learning plant models can complement physics-based hydraulic models during hardware development and controller calibration when representative test-stand data are available.
We present a novel approach to regression tasks using classification which is motivated by the mechanism used by fruitflies to sense their environment. Specifically, we formulate a general framework for learning nonlinear input-output relationships by replacing complex global surrogate models with a finite library of representative local patterns. Since scientific data often occupy limited and recurring regions of the input space, we generate predictions by measuring similarities between a query and stored patterns, then combining their associated responses through weighted reconstruction. We apply this approach to nonlinear dynamical systems, data-driven regression, and physics-informed learning using suitable embeddings and similarity measures. For dynamical systems, our offline-online workflow extracts patterns from data or governing equations during the offline phase, while online prediction requires only similarity evaluation and response aggregation. This structure helps us reduce computational and memory demands while providing explicit control over the trade-off among accuracy, storage, and inference cost.
Hybrid models that combine physics-based and data-driven components have shown strong potential for achieving accuracy and interpretability in control applications. While recent methods have made progress in incorporating physical consistency, challenges remain in scalability, robustness to noise, and control of model complexity. This paper proposes a Physics-Encoded Modular Hybrid Layer (PE-MHL) framework, in which a baseline physics-based model is incrementally refined through the addition of new sub-models, where each new component adds complexity while preserving what previous components have already learned. We establish a theoretical guarantee for this construction: with a least-squares initialization of each new sub-model, the training error is monotonically non-increasing in the number of sub-models and provably converges. Empirical evaluations on a nonlinear NARX benchmark and the Quanser Aero 2 platform demonstrate that PE-MHL outperforms equivalently sized monolithic networks in both accuracy and generalization, while also providing more stable training dynamics and better preservation of underlying data structures.
Developing autonomous hydraulic excavators is constrained by limited access to physical machines and the high cost of real-world experimentation. This paper proposes a simulation-to-real framework for learning a system-level digital surrogate using Long Short-Term Memory (LSTM) networks. Instead of modeling internal dynamics, the excavator is treated as an input-output operator, and the surrogate is trained to reproduce its closed-loop behavior under identical control inputs. The approach is first validated in a MuJoCo simulation environment and then transferred to a real excavator. To address measurement inconsistencies in real-world data, a consistency-aware state estimation method based on adaptive Kalman filtering is introduced. Experimental results demonstrate that the learned surrogate achieves high fidelity in both angular velocity and long-horizon trajectory reproduction under closed-loop autoregressive evaluation. These results confirm that the proposed model can serve as a drop-in surrogate for both simulation and physical systems, enabling scalable and efficient development of excavation automation algorithms.