Abstract
With increasing demand for automation and user convenience in modern vehicles, Power Operated Tailgates (POT) have become standard in premium and mid-segment cars. However, validating such systems—comprising electronic control units (ECUs), sensors, actuators, and mechanical components poses significant challenges in safety, reliability, and cost. This paper introduces a Hardware-in-the-Loop (HiL) based validation framework that allows comprehensive, automated, and safe testing of POT systems without depending on full vehicle prototypes.
The HiL platform integrates Real Time Hardware and Real Time software with dynamic models to simulate real-world behaviors. It enables automated validation of normal and fault scenarios—such as open/close commands, anti-pinch protection, voltage sensitivity, and communication errors—ensuring robust system performance. The proposed framework accelerates development, improves test coverage, and supports early fault detection, making it a strategic enabler for future vehicle system validation.
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Working Principle
The Hardware-in-the-Loop (HiL) setup for Power Operated Tailgate (POT) testing operates as follows:
1. System Components: The test setup includes the actual POT ECU, a simulated Body Control Module (BCM) using MATLAB/Simulink, a real-time , and input simulation interfaces (e.g., GUI for driver switch, FOB, rear handle, kick sensor).
2. Real-Time Simulation:
o The plant models simulate motor dynamics, latch mechanism, sensor feedback, and system behavior.
o These models are compiled into real-time executables using Simulink Coder and deployed on real time controller.
3. Communication and Control:
o The ECU communicates with the simulated environment via CAN and analog/digital I/Os.
o Commands like open/close or fault injections are issued, and the ECU’s responses are monitored in real time.
4. Automated Testing:
o Functional, safety, and boundary test cases are scripted and executed automatically using SW and Simulink Test Manager.
o All signal transitions, diagnostic messages, and actuator actions are logged for objective analysis.
5. Validation Metrics:
o Voltage robustness, current signatures, and timing validations are used to evaluate system health and behavior under various test scenarios.
This controlled simulation loop ensures safe, repeatable, and comprehensive testing of the tailgate system without requiring a physical vehicle setup.
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Summary
The paper proposes a novel approach to validating Power Operated Tailgate (POT) systems using a real-time Hardware-in-the-Loop (HiL) platform. Traditional testing methods struggle with safety, cost, and test coverage—especially for fault and safety-critical scenarios. To address these issues, the authors implemented a HiL framework using real time hardware, real time software, and MATLAB/Simulink models that simulate the physical behavior of the tailgate and associated sensors and actuators.
This setup allows for:
• Automated execution of functional and safety test cases (e.g., open/close, anti-pinch, stall detection).
• Injection of electrical faults and boundary condition simulations (e.g., voltage dips, high current loads).
• Seamless integration with diagnostic tools like CANalyzer for network analysis.
Key benefits include:
• Reduction of manual testing effort by 40%.
• Early-stage detection of design flaws and electrical issues.
• Minimized dependency on full vehicle prototypes.
• High scalability and repeatability across development phases.
The system successfully validated over 100+ test scenarios, showing strong performance under both normal and stress conditions. The methodology sets a new standard for POT validation and has potential for broader application in other automotive mechatronic systems.