Development of digital twin of a three-plunger hydraulic pump

Authors

  • Michael A. Zhuravkov Belarusian State University, 4 Niezaliezhnasci Avenue, Minsk 220030, Belarus
  • Mikhail A. Nikolaitchik Belarusian State University, 4 Niezaliezhnasci Avenue, Minsk 220030, Belarus
  • Ivan N. Karpovich Belarusian State University, 4 Niezaliezhnasci Avenue, Minsk 220030, Belarus
  • Alexander A. Poliahoshko Belarusian State University, 4 Niezaliezhnasci Avenue, Minsk 220030, Belarus
  • Yu Guangbin Harbin Institute of Technology, 92 West Dazhi Street, Harbin 150001, China
  • Ma Wansheng Chongqing Pump, 8 Jingsheng Road, Chongqing 400033, China

Keywords:

digital twin, plunger hydraulic pump, fault simulation, predictive model

Abstract

This paper presents the development and modelling of a digital twin of a triplex plunger pump. Its mathematical model is based on the physical process. The model takes into account the operating parameters and interaction of components inside the pump. Data on three key types of malfunctions are used to train the prediction system. The faults considered are leaks, inlet channel blockages, and bearing wear, as well as combinations thereof. The digital twin allows the characteristic signs of incipient failures to be identified at an early stage and the specific cause to be found.

Author Biographies

  • Michael A. Zhuravkov, Belarusian State University, 4 Niezaliezhnasci Avenue, Minsk 220030, Belarus

    doctor of science (physics and mathematics), full professor; head of the department of theoretical and applied mechanics, faculty of mechanics and mathematics

  • Mikhail A. Nikolaitchik, Belarusian State University, 4 Niezaliezhnasci Avenue, Minsk 220030, Belarus

    PhD (physics and mathematics), docent; leading researcher at the department of theoretical and applied mechanics, faculty of mechanics and mathematics

  • Ivan N. Karpovich, Belarusian State University, 4 Niezaliezhnasci Avenue, Minsk 220030, Belarus

    junior researcher at the department of theoretical and applied mechanics, faculty of mechanics and mathematics

  • Alexander A. Poliahoshko, Belarusian State University, 4 Niezaliezhnasci Avenue, Minsk 220030, Belarus

    student at the faculty of mechanics and mathematics

  • Yu Guangbin, Harbin Institute of Technology, 92 West Dazhi Street, Harbin 150001, China

    doctor of science (physics and mathematics); professor at the school of mechatronics engineering

  • Ma Wansheng, Chongqing Pump, 8 Jingsheng Road, Chongqing 400033, China

    head of the research department

References

  1. Parrott A, Warshaw L. Industry 4.0 and the digital twin: manufacturing meets its match. [S. l.]: Deloitte University Press; 2017. 18 p. (A Deloitte series on Industry 4.0, digital manufacturing enterprises, and digital supply networks).
  2. Liu M, Fang S, Dong H, Xu C. Review of digital twin about concepts, technologies, and industrial applications. Journal of Manufacturing Systems. 2021;58(part B):346 –361. DOI: 10.1016/j.jmsy.2020.06.017.
  3. Hananto AL, Tirta A, Herawan SG, Idris M, Soudagar MEM, Djamari DW, et al. Digital twin and 3D digital twin: concepts, applications, and challenges in Industry 4.0 for digital twin. Computers. 2024;13(4):100. DOI: 10.3390/computers13040100.
  4. Wang Z, Gupta R, Han K, Wang H, Ganlath A, Ammar N. Mobility digital twin: concept, architecture, case study, and future challenges. IEEE Internet of Things Journal. 2022;9(18):17452–17467. DOI: 10.1109/JIOT.2022.3156028.
  5. Bhatti G, Mohan H, Singh RR. Towards the future of smart electric vehicles: digital twin technology. Renewable and Sustainable Energy Reviews. 2021;141:110801. DOI: 10.1016/j.rser.2021.110801.
  6. Zhuravkov MA, Nikolaitchik MA. Construction of mine elements digital twins. Mining Mechanical Engineering and Machine-Building. 2023;2:5 –14. Russian. EDN: ARDPNA.
  7. Zhuravkov MA, Nikolaitchik MA, Wang Z, Yu G. Fatigue life prediction of hoist drum-rail contact pair based on digital twin. Results in Engineering. 2025;26:105271. DOI: 10.1016/j.rineng.2025.105271.
  8. Andenyangtso NE, El-Suleiman A, Chollom TD, Yekini B. Development of a test stand for determining the technical condition of a plunger pump. FUW Trends in Science & Technology Journal. 2024;9(1):410 – 414.
  9. Lian Z, Liu Y, Lin T, Li L, Lei Z, Han C. Study on the fluid flow rule of five-cylinder plunger pump hydraulic end. Petroleum. 2018;4(4):457– 465. DOI: 10.1016/j.petlm.2017.11.001.
  10. Velikanov NL, Naumov VA, Koryagin SI. Characteristics of plunger pumps. Russian Engineering Research. 2018;38(6):428 – 430. DOI: 10.3103/S1068798X18060175.
  11. Karassik IJ, Messina JP, Cooper P, Heald CC. Pump handbook. 4th edition. New York: McGraw-Hill; 2007. 1632 p.
  12. Cadima EL. Fish stock assessment manual. Rome: FAO; 2003. XX, 161 p. (FAO fisheries technical paper; No. 393).
  13. Rivera DL, Scholz MR, Fritscher M, Krauss M, Schilling K. Towards a predictive maintenance system of a hydraulic pump. IFAC-Papers Online. 2018;51(11):447– 452. DOI: 10.1016/j.ifacol.2018.08.346.
  14. Green E, Taylor L. Development of a predictive maintenance framework for hydraulic systems using IoT and machine learning. International Journal of Mechanical Industrial and Control Systems Engineering. 2024;1(2):48 –53. DOI: 10.61132/ijmicse.v1i2.83.
  15. Box GEP, Hunter JS, Hunter WG. Statistics for experimenters: design, innovation, and discovery. 2nd edition. Hoboken: Wiley-Interscience; 2005. XVII, 633 p. (Wiley series in probability and statistics).
  16. Montgomery DC. Design and analysis of experiments. 9th edition. Hoboken: John Wiley & Sons; 2017. XV, 734 p.
  17. van Drongelen W. Signal processing for neuroscientists: an introduction to the analysis of physiological signals. Amsterdam: Academic Press; 2007. Chapter 6, Continuous, discrete, and fast Fourier transform; p. 91–105. DOI: 10.1016/B978-012370867-0/50006-1.
  18. Ma L, Jiang A, Jiang W. The intelligent diagnosis of a hydraulic plunger pump based on the MIGLCC-DLSTM method using sound signals. Machines. 2024;12(12):869. DOI: 10.3390/machines12120869.
  19. Patseika PG, Rouba YA, Smatrytski KA. On the approximation of conjugate functions and their derivatives on the segment by partial sums of Fourier – Chebyshev series. Journal of the Belarusian State University. Mathematics and Informatics. 2024;2:6 –18. EDN: ZITNRS.
  20. Lughofer E, Sayed-Mouchaweh M, editors. Predictive maintenance in dynamic systems: advanced methods, decision support tools and real-world applications. Cham: Springer; 2019. XIII, 567 p. DOI: 10.1007/978-3-030-05645-2.
  21. Patseika PG, Rouba YA. Fejer means of rational Fourier – Chebyshev series and approximation of function ${left| x right|^s}$. Journal of the Belarusian State University. Mathematics and Informatics. 2019;3:18 –34. Russian. DOI: 10.33581/2520-6508-2019-3-18-34.

Downloads

Additional Files

Published

2026-09-25

Issue

No. 2 (2026): Journal of the Belarusian State University. Mathematics and Informatics

Section

Theoretical and Applied Mechanics

License

Copyright (c) 2026 Journal of the Belarusian State University. Mathematics and Informatics

Creative Commons License

This work is licensed under a Creative Commons Attribution-NonCommercial 4.0 International License.

The authors who are published in this journal agree to the following:

  1. The authors retain copyright on the work and provide the journal with the right of first publication of the work on condition of license Creative Commons Attribution-NonCommercial. 4.0 International (CC BY-NC 4.0).
  2. The authors retain the right to enter into certain contractual agreements relating to the non-exclusive distribution of the published version of the work (e.g. post it on the institutional repository, publication in the book), with the reference to its original publication in this journal.
  3. The authors have the right to post their work on the Internet (e.g. on the institutional store or personal website) prior to and during the review process, conducted by the journal, as this may lead to a productive discussion and a large number of references to this work. (See The Effect of Open Access.)

How to Cite

[1]
Zhuravkov, M. et al. 2026. Development of digital twin of a three-plunger hydraulic pump. Journal of the Belarusian State University. Mathematics and Informatics. 2 (Sep. 2026), 62–76.