This paper presents applied methodologies and results from real-time Hardware-in-the-Loop (HIL) testing of electrified powertrain systems, based on experience gained during advanced development programs in the electric vehicle (EV) sector. It outlines how HIL accelerated control software validation, enhanced fault coverage, and improved development cycles for critical powertrain components such as Vehicle Control Units (VCU), Inverters (INV), Chargers, DC-DC Converters (DCDC), and Electric Motors (EM).
As electrified propulsion systems grow in complexity to meet performance, efficiency, and safety demands, robust and scalable validation techniques are essential. Modern EV powertrains integrate multiple ECUs managing distinct subsystems, requiring thorough testing of both individual components and their interactions. To address this, a real-time HIL test bench was developed to simulate a broad range of driving conditions, powertrain operating scenarios, and fault cases.
The test bench supports advanced fault injection and scenario-based testing, enabling engineers to evaluate system behavior under critical conditions such as transient loads, communication faults, sensor errors, and system degradations—without relying on physical prototypes. By replacing physical hardware with a real-time simulator, this setup facilitates efficient closed-loop validation of powertrain control algorithms and subsystem integration.
Developing the HIL bench involves integrating detailed real-time models of EV powertrain components with high-performance simulation hardware and communication interfaces replicating vehicle networks such as CAN and Ethernet. The platform must support modular ECU connections and allow flexible scenario scripting for automated testing. Implementation of comprehensive fault injection capabilities and data acquisition ensures thorough verification of control logic and system resilience. Close collaboration between system modeling, control algorithm development, and hardware configuration teams is critical to ensure accurate and effective testbench operation.
This methodology has helped accelerate development timelines, detect integration issues early, and ensure compliance with stringent safety and performance standards. The paper details the design, implementation, and benefits of the HIL testing approach, emphasizing its crucial role in advancing next-generation electrified propulsion systems for electric and autonomous vehicles.