Methodical Approach for the Development of Multi Domain Testing Environments for Stable Operation Under Impulse Excitation

Repeated impulsive loads are critical for both structural integrity and human vibration exposure in power tools such as rotary hammers. Therefore, they need to be evaluated in a precise manner in order to consider them in design of these power tools. However, existing testing environments used to gain insights often fail to reproduce highly transient impact behaviour in a controllable and adjustable way, particularly when different physical domains, like mechanic and hydraulic, and workpiece properties must be represented. This paper proposes a fivestep, multidomaincapable methodical development approach that operationalises Ewins’ structural dynamics toolkit into an approach for developing testing environments under impulse excitation, covering virtual modelling, realsystem characterisation, model parametrization, derivation of design parameters, and testing. For evaluation this method, is then applied to a hydraulically based substitute workpiece for rotary hammers to achieve adjustable damping behaviour and equivalence in effect to different real concrete workpieces within defined operating limits. The results demonstrate that the proposed approach enables the systematic development of testing environments and substitute workpieces that realistically reproduce impact behaviour while remaining reproducible, adjustable and suitable for integrated modelling, identification and validation.