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It is not uncommon for complex engineering products to undergo several design iterations due to changing market expectations or inadequate performance. In such circumstances, a prototype is generally available that could be used for performance analysis before a revision to the design is made. The availability of a prototype can be an invaluable tool for the analysis of the impact of potential design changes on the system performance. In this paper, a process is proposed for the derivation of a physical model that could be used for design analysis. The process uses model identification for determination of model complexity and numerical optimization for estimation of model parameters. This process is applied to a new pneumatic fan clutch system that has been developed to improve the efficiency of engine temperature regulation in heavy-duty commercial vehicles. This system is currently in a prototype phase and its detailed physical model is required for design trade-off analysis

This paper describes the design strategy adopted for developing a new high performance actuation system referred to as the ElectroHydraulic Actuator (EHA). The design approach can be divided into fives phases that include: pre-conceptual analysis, conceptual design, preliminary design, detailed design and, integration and test. An important aspect of the design process is the use of modeling and simulation for the analysis, sizing and selection of off-the-shelf parts, and for the detailed design of new custom made components. EHA is based on hydrostatic transmission. It is a unique device with its own characteristics and requires hydraulic components that are specifically tailored to its needs. A prototype of EHA has been produced and has demonstrated an extremely high level of performance. The performance of this prototype complies with design requirements and validates the chosen design approach.