Hardware-In-The-Loop (HIL) Testing
Hardware-in-the-loop HIL testing in automotive domain eliminates the requirement for real world testing by making the product believe that it is in real world and test it for predefined real world conditions to evaluate it. The best part is that it can be tested for almost all possible conditions within the lab.
Our engineers design and create test cases covering almost all possible scenarios. The test cases can also be prepared or customized based on inputs from client’s teams. We also provide inputs for design changes for improvement of the product. We support validation testing of battery management system (BMS), electric vehicle batteries, motor controllers, power inverters and motors.
Signal Level HIL Testing
This is the basic level which incorporates a development ECU that is flashed with a motor control algorithm. The I/O’s of the ECU are mapped to the HIL system. Here power inverter and the motor are in form of MATLAB models. Inputs and outputs of these models are mapped to the ECU through HIL system.
- Algorithm testing for development ECU.
- Inverter and Motor models are simulated and design changes are made for efficiency.
Power Stage Level HIL Testing
At this stage the production ECU is tested with power inverter hardware. Motor controller output and power inverter feedback is analysed along with motor shaft position and feed back coming from the motor model.
The I/O’s of the ECU are mapped to the HIL system. Inverter current signals will be mapped to the ECU through HIL system. Motor feedback generated by the motor model will be provided to the ECU through HIL System.
- Production ECU can be tested for algorithm.
- Power inverter is tested for efficiency and output.
- Motor model is simulated and required design changes are made in motor model to increase efficiency.
Vehicle Level HIL Testing
Here we use a complete powertrain which is run according to various test cases incorporating simple to tough scenarios. ECU outputs are analysed with feedback signals generated by power inverter and motor in form of current signals and motor shaft position signal.
- Testing of algorithm and efficiency of production ECUs.
- Power inverter is tested for efficiency and power delivery capability.
- Motor is tested for efficiency.
- Power inverter and Motor are compared with their respective models and results are correlated.
Apart from this Advanced Structures supports in model designing of inverters and motors.