HIL & Simulation Services

Hardware-in-the-loop benches and plant models for embedded controller validation: what we build, how it connects to your hardware, and how a project runs.

Bench types

Each bench is scoped to the controller under test and the tests it has to support.

Single-controller benches

One ECU or controller, its full I/O and a plant model. Used for function testing, diagnostics and regression on a single unit.

Multi-controller benches

Several controllers connected through their real communication networks, with simulation of the nodes that are not physically present.

Fault-insertion setups

Pin-level fault insertion (open circuit, short to ground or supply) to exercise diagnostic and safety functions reproducibly.

I/O integration

Connecting the controller to the simulator is usually where most of the bench effort goes.

Signal conditioning

Breakout boards and conditioning for analog, digital and PWM signals, including level adaptation and load simulation where required.

Communication buses

Integration of the controller's communication interfaces and simulation of the missing bus traffic.

Wiring and documentation

I/O allocation lists, wiring diagrams and harness specifications, delivered with the bench so it can be maintained and extended.

Real-time targets

Plant models run on a real-time target at a fixed step size, synchronised with the controller's I/O.

Model deployment

Configuration of the real-time target, model build and deployment, and mapping of model signals to physical I/O channels.

Timing budget

Step size chosen against the dynamics being simulated, with execution-time and overrun monitoring on the target.

Plant models

Models are built for the fidelity the test actually needs, then validated and prepared for real-time execution.

Parameterisable plant models

Electric motor, thermal and hydraulic models with parameters stored separately from the model, so they can be adapted to your hardware.

Custom model development

Models built to your specification and validated against your measurement data.

Model integration

FMI/FMU export, co-simulation setup and integration into your existing toolchain.

Typical project workflow

Steps are adjusted to the project, but most engagements follow this sequence.

  1. 1

    Scope

    Controller under test, test objectives, required I/O and the plant behaviour that must be simulated.

  2. 2

    Architecture

    Bench architecture, I/O allocation, real-time target selection and model fidelity, agreed before any build work.

  3. 3

    Models

    Plant model development or adaptation, offline validation, then real-time readiness checks.

  4. 4

    Bench build

    Hardware integration, signal conditioning and wiring, following the agreed I/O allocation.

  5. 5

    Commissioning

    Closed-loop tests with the controller, then acceptance tests against the agreed scope.

  6. 6

    Handover

    Documentation, model and bench sources, and support for your team while the bench goes into use.

Discuss your project

Describe the controller, the tests you need to run and your timeline. We reply with questions or a quote.

Request a quote