HIL Commissioning – Low Voltage System HIL for EV Truck

ABSTRACT

Hardware-in-the-loop (HIL) testing is a pivotal validation and commissioning methodology in embedded systems and automotive engineering. By integrating real hardware components with real-time simulations, HIL provides a controlled, cost-effective, and repeatable platform to test and optimize electronic control units (ECUs) and embedded systems under realistic conditions without relying on physical prototypes. This approach identifies design flaws early, enhances system reliability, and reduces development costs. As automotive systems grow more complex with advancements in electrification, advanced driver-assistance systems (ADAS), and autonomous technologies, HIL testing ensures robust validation across functionalities, from powertrains to sophisticated sensor fusion algorithms. Its adaptability and scalability make HIL indispensable in modern engineering workflows.

This paper delves into the principles and applications of Methodica’s Hardware-in-the-Loop (HIL) commissioning within the automotive sector, emphasizing its significance in enhancing the reliability and performance of modern vehicles.

HIL systems integrate real-time simulation models with hardware interfaces to mimic diverse operational scenarios, enabling efficient validation of ECUs and subsystems under varying conditions. Key topics explored include the architecture of HIL setups, comprising simulation platforms, actuator interfaces, and real-time processing units, along with the methodologies employed to customize these systems for specific automotive applications.

The paper also demonstrates how Methodica’s HIL Test as a Service’ model accelerates development timelines, ensures compliance with stringent industry standards, and supports emerging technologies like electric vehicles (EVs) and automated driving systems.

INTRODUCTION

This Hardware-in-the-loop system was developed for a Truck OEM which intended to offer a proprietary all-electric chassis adaptable for Class 3 to 5 vehicles, supporting applications in last-mile delivery, construction, utilities etc.

The customer encountered significant challenges in testing due to limited vehicle availability, where even minor functional tests had to wait for the vehicle to be in a high-voltage state. Additionally, as the testing vehicle was a prototype, it experienced frequent downtimes caused by issues with the high-voltage systems, further complicating the testing process. Since the scope involves integration testing, a Hardware-in-the-Loop (HIL) setup was implemented, allowing ECUs to be frequently upgraded and updated. This enabled the customer to test scenarios without relying on vehicles and to automate test cases for functional validation and diagnostic fault validation effectively.

The intended HIL for the customer had a lead time of 6-8 months, which did not align with the customer’s testing timeline. To address this, Methodica introduced the ‘HIL Test as a Service’ solution. A plan was devised to construct a Minimum Viable Product (MVP) HIL within a few months. The ECU rack was built, and a HIL system was developed using a leasing model, enabling the customer to meet their testing requirements within the specified timeline. Once the originally planned HIL arrived after its 8-month lead time, the configurations and setup were seamlessly ported to the new system.

HIL ARCHITECTURE

Hardware-in-the-loop (HIL) systems are composed of three major components: simulation platforms, actuator interfaces, and real-time processing units. Together, these elements enable accurate and efficient testing of automotive embedded systems by simulating real-world conditions and seamlessly integrating hardware into the loop.

1. Actuator Interfaces:

Actuator interfaces bridge the gap between the virtual simulation environment and the physical hardware being tested. These interfaces connect the test equipment (e.g., ECUs or sensors) to the simulated system, enabling the hardware to interact with the virtual model as it would in a real-world application. This component includes signal conditioning hardware, input/output (I/O) modules, and communication protocols such as CAN, LIN, or Ethernet. The actuator interfaces to ensure that the responses of the hardware are accurately captured and fed back into the simulation for real-time analysis.

2. Simulation Platforms:

The simulation platform forms the backbone of an HIL setup. It involves detailed mathematical and physical models that replicate the behaviour of a vehicle’s subsystems, such as the powertrain, suspension, braking system, or environmental dynamics These models run on high-performance simulation software, providing the test environment where real-world conditions like road gradients, weather variations, and dynamic loads are accurately represented. The simulation platform ensures that test conditions are reproducible, consistent, and customizable, which is critical for system validation across various scenarios.

3. Real-Time Processing Units:

Real-time processing units are specialized hardware devices responsible for executing simulation models and processing test data in real-time. These units provide the computational power needed to handle the high-speed data exchanges between the simulation platform and the actuator interfaces. Real-time processing ensures that the system operates without delays, which is critical for accurate testing of safety-critical systems like ADAS, EV battery management, and autonomous driving functionalities. Usually, the HIL provided by dSPACE, National Instrument Typhoon etc. integrated the actuator interface and real-time processing units.

This structured and modular approach to HIL setup allows for efficient, scalable, and accurate testing, which is essential for developing reliable automotive systems.

SERVICE MODEL

Methodica provides two highly specialized pathways for Hardware-in-the-Loop (HIL) commissioning: HIL Environment Development at Methodica HIL (Leased System) and NEW-HIL Procurement, Development, and Commission Process. These approaches are designed to address diverse project needs, ensuring flexibility, cost-efficiency, and scalability for automotive system validation.

1. HIL Environment Development at Methodica HIL (Leased System)

This path enables clients to utilize Methodica’s fully operational HIL facilities on a leased basis, eliminating the need for hardware investment while accelerating the development process. The process involves several structured phases:

• I/O Mapping Phase: Signals between the ECU and HIL system are analyzed and mapped to ensure proper integration and compatibility with the testing framework.
• HIL Commissioning & Integration (MTech HIL): Methodica’s expert team configures the leased HIL system to align with the project’s specific testing requirements, ensuring seamless integration with client-provided ECUs or subsystems.
• V&V Regression: Ongoing regression testing is conducted to validate software updates or modifications, ensuring consistent reliability and compliance with project specifications.

This approach is ideal for short-term projects or clients seeking a ready-to-use environment with professional support, offering rapid validation capabilities without infrastructure investments.

2. NEW-HIL Procurement, Development, and Commission Process

For clients requiring a tailored, dedicated HIL setup, Methodica offers an end-to-end solution that involves the design, development, and commissioning of a new HIL system. This comprehensive process includes the following key phases:

• I/O Mapping: Detailed mapping of all signal inputs and outputs between the ECU and the HIL system ensures proper communication and compatibility with the custom setup.
• HIL Platform Selection: Based on project-specific needs, Methodica identifies the most suitable HIL platform, considering factors such as computational requirements, simulation fidelity, and scalability.
• HIL Procurement Order: Methodica collaborates with clients to finalize and place procurement orders for the chosen HIL platform and associated components.
• HIL Platform Procurement Lead Time: This phase involves managing the lead time for hardware delivery, including tracking and coordination to ensure the timely availability of components.
• Typhoon: 3-4 months.
• NI HIL: 4-6 months.
• dSPACE HIL: 6-9 months.
• HIL Commissioning & Integration: The new HIL system is configured and integrated into the client’s workflow, ensuring seamless communication between simulation models, hardware interfaces, and the ECU.
• HIL Deployment & U.A.T. (User Acceptance Testing): The HIL system is deployed at the client’s facility, followed by user acceptance testing to validate functionality, performance, and readiness for operational use.
• ECU Software Verification & Validation (V&V): The ECU software is rigorously tested in real-time simulated environments, allowing for thorough validation of functional and performance aspects under diverse scenarios.

CASE STUDY: CLASS 3 EV TRUCK PROJECT

In this project with a Class 3 truck EV OEM, Methodica successfully addressed complex requirements involving a mix of Real, Modeled, and simulated ECUs. The real ECUs included all Low Voltage and Non-Drive Dynamic Controllers. Modelled ECUS encompassed High Voltage and Drive Dynamic Controllers and basic simulation for Comfort and Other Peripheral Controllers.

• For Real ECUs, the process starts with identifying the pin configurations, which are then meticulously mapped to the dSPACE HIL system. This involves designing and constructing a custom wiring harness and commissioning the HIL setup to ensure seamless communication between the physical hardware and the virtual simulation environment.

• For Simulated ECUs, the process begins with analyzing DBC files to understand the network communication structure. A static rest bus simulation is then prepared using the CANoe tool Platform/ Dspace Bus Manger & MATLAB model. Additionally, a GUI is developed to enable signal value modifications, replay mechanisms are configured to replicate specific scenarios, and logged data is analyzed and visualized to evaluate and verify ECU interactions.
• For Modelled ECUs, we create linear plant models to replicate the real-time behaviour of specific ECUs. Dynamic systems, such as motor control units, are developed using tools like MATLAB and Control Desk, while discrete systems, such as drive shift selectors, are simulated using CANoe CAPL scripting. This comprehensive approach ensures robust validation by seamlessly integrating hardware, software, and simulated environments, enabling thorough testing and optimization of system performance under real-world conditions.

MVP HIL vs Customized Target HIL:

At the start of the project, the customer leased Methodica’s dSPACE HIL system to begin testing as early as possible. Within two months, Methodica delivered a fully functional HIL system. However, the initial system supported only two CAN channels, whereas the project required four. Methodica deployed an additional CAN case to address this limitation to enable communication between the HIL and ECUs. Recognizing the need for a more advanced setup, the customer subsequently ordered a custom HIL system from dSPACE, specifically tailored to their project requirements.

After nine months, the custom HIL system was delivered. Methodica seamlessly migrated the plant model and wiring harness to the new system, ensuring proper configuration and optimal performance. This case demonstrates Methodica’s expertise in providing rapid HIL solutions, adapting to evolving project needs, and ensuring smooth transitions for complex automotive projects.

Plant Models to support the architecture

In our Simulink model for automotive systems, each block represents a functional subsystem that simulates a specific aspect of the vehicle’s behaviour or interaction with its environment. Here’s a general overview of the main blocks and their functionalities:

• Electrical System: The Electrical System block models the vehicle’s electrical architecture, including components like the battery, alternator, DC/DC converters, and power distribution systems. It simulates energy storage, generation, and distribution, ensuring that power requirements for various subsystems are met. This block is crucial for analyzing the performance of electric vehicle (EV) Systems including battery state of charge (SOC) and energy efficiency.
• Electrical Drive Unit (EDU): The Electrical Drive Unit block simulates the electric motor, inverter, and associated control systems responsible for propulsion. It captures motor dynamics, torque generation, and power conversion from electrical to mechanical energy. This block enables engineers to study the drive system’s efficiency, performance, and thermal behaviour under various driving conditions.
• Vehicle Dynamics: The Vehicle Dynamics block models the mechanical behaviour of the vehicle, including, chassis, drivetrain, tyres, and linear dynamics. It computes parameters like acceleration, braking, and road load. This block is essential for understanding how the vehicle behaves in different driving scenarios and interacts with the environment.
• Driver: The Driver block simulates driver inputs such as throttle, brake, and steering commands. It often incorporates control algorithms like PID or fuzzy logic to represent human driving behaviour or automated driving systems.
• Environment: The Environment block represents external factors affecting the vehicle, such as road conditions, gradients, weather, and traffic. It provides realistic inputs to the Vehicle Dynamics block, allowing engineers to study how these external factors impact vehicle performance, safety, and efficiency.

• Domain Control: The Domain Control block coordinates and manages interactions between various subsystems, such as the powertrain and ESP Controller. It typically includes supervisory control algorithms that ensure the system operates optimally under different conditions.
• Input/Output (I/O): The Input/Output block handles communication between the Simulink model and external interfaces, such as Hardware-in-the-Loop (HIL) systems or real-time controllers. It facilitates the transmission of sensor signals, actuator commands, and other data, ensuring seamless integration between the virtual model and physical hardware during testing or validation.

By combining these blocks in a Simulink model, Methodica created a comprehensive simulation of the vehicle system, enabling analysis, optimization, and validation of its performance under realistic conditions.

CONCLUSION

Methodica provides two flexible and tailored solutions for Hardware-in-the-Loop (HIL) commissioning. These approaches are designed to address a wide range of testing needs in the automotive industry, ensuring flexibility, efficiency, and scalability.

1. Methodica HIL (Leased System): A Cost-Effective and Quick Solution

The leased HIL system is an ideal choice for clients who need immediate access to a ready-to-use HIL environment.

Key features include:

• Immediate Access: Rapid deployment eliminates long lead times and allows clients to begin testing promptly.
• Cost Efficiency: The leasing model removes the need for upfront capital investment, reducing financial strain.
• Expert Support: Methodica provides technical assistance, ensuring seamless operation and troubleshooting.
• Scalability: The system can be adapted to accommodate changing project requirements throughout the development cycle.

By leveraging the leased system, clients can perform ECU testing and validation without waiting for long procurement cycles, accelerating their development timelines.

2. NEW-HIL Procurement, Development, and Commissioning Process: Tailored for Long-Term Needs

For clients requiring a fully customized solution, Methodica offers the NEW-HIL pathway. This approach is ideal for long-term projects that demand advanced infrastructure and dedicated testing capabilities.

Key features include:

• Custom Design and Development: The HIL system is built to meet specific project requirements, supporting advanced validation scenarios.
• Dedicated Infrastructure: A permanent HIL setup ensures long-term reliability and scalability.
• Comprehensive and Future Ready Testing Capabilities: The system supports functional, diagnostic, and integration testing under simulated real-world conditions.
• End-to-End Support: Methodica oversees procurement, setup, and commissioning, ensuring a smooth transition into the client’s workflow.

Why Choose Methodica?

Methodica Technologies, headquartered in Michigan, is a trusted engineering partner for OEMs and Tier-1 suppliers, enabling their transition to smart and electric mobility. With extensive expertise in system design, software development, integration, and validation, we deliver innovative and reliable engineering solutions tailored to mission-critical applications.

Our Core Engineering Services Include:
✔ System Design & Architecture Development – Requirements engineering, MBSE (Model-Based System Engineering), system architecture, and specifications.
✔ Software & Controls Development – Base software/firmware development, controls engineering, SIL/MIL testing, and software re-architecture.
✔ Software & System Integration and Verification – HIL setup, test automation, system integration, and verification lifecycle management.
✔ System Validation – Comprehensive validation from component level to full vehicle testing, including lab car and in-vehicle validation.
✔ Technology Adoption – Transitioning to electrification, ADAS (L2, L3) implementation, and advanced system integrations.
✔ Process & Compliance – Functional safety, cybersecurity consulting, and regulatory adherence.
✔ Data Collection, Analytics & Connectivity – Real-time data processing, connectivity solutions, and predictive analytics.

With extensive experience in these domains, we are eager to explore a collaborative partnership with Analog Devices to drive innovation and engineering excellence.

From CEO`s Desk

Vikram Verma is a visionary engineering leader and entrepreneur with expertise in embedded systems, hardware-in-the-loop (HIL) testing, and automation. He holds a Master of Business Administration (MBA) from Walsh College and a Master of Engineering (M.Eng.) in Electrical and Electronics Engineering from the Illinois Institute of Technology.

Vikram began his career as an Embedded Systems Engineer at Panasonic Automotive Systems. He then took on roles as Design Architect for HIL Systems at Continental Automotive Systems and Engineering Manager at Manitowoc, further deepening his expertise in all forms of Development and Verification & Validation.

In April 2014, Vikram founded Methodica Technologies, a company specializing in HIL, Rapid Control Prototyping (RCP), and Python-based Test Automation. Starting in the USA, he successfully expanded the business globally, establishing operations in Germany, Canada, India, Mexico, Austria, and the UK. Under his leadership, Methodica Technologies has become a trusted partner for automotive, aerospace, railways, and food service industries, delivering cutting-edge engineering solutions, test automation, and model-based development strategies. His ability to bring cross-industry innovations has driven efficiency, cost savings, and product reliability, making a significant impact on the global engineering landscape.

For any inquiries or to discuss how Methodica can support your projects, please reach out to us at operations@methodicatech.com.