Hardware-in-the-Loop
Hardware-in-the-Loop
Data logging for reproducible control unit and system tests
Hardware-in-the-Loop (HiL) is an established testing method in vehicle development. It involves testing control units under reproducible laboratory conditions while the vehicle, sensors, or actuators are fully or partially simulated.
This allows software functions to be validated before vehicle testing. Errors can be detected, reproduced, and analyzed at an early stage.
During a HiL test, communication data from multiple vehicle networks and measurement data from the test bench systems are generated. The synchronous recording of this data forms the basis for analyzing system behavior and evaluating test results.
Typical experimental setup
How are electronic control units validated using hardware-in-the-loop?
In a HiL test, the control unit under test is connected to a simulated vehicle environment. While the control unit operates using real hardware, the vehicle, sensors, or actuators are fully or partially replaced by simulation models. This enables development and validation tests to be conducted independently of a real vehicle. Errors can be reproduced under identical conditions, and different software versions can be objectively compared.
Application
Testing control units and functions realistically
Challenge
Synchronized real-time data acquisition
Interfaces
CAN / CAN FD, LIN, FlexRay, and more
Bandwidth
Data Throughput: 2–16 Gbit/s Storage Requirements: 2–32 TB
Test Setup and Test Environment
The test setup of a hardware-in-the-loop system connects the real control unit with a simulated vehicle environment. Sensors, actuators, and other vehicle components are emulated using models, and the corresponding signals are generated and processed in real time.
The test environment enables the targeted and reproducible replication of various operating conditions and driving situations. Boundary cases and fault scenarios can also be simulated, allowing control units and vehicle functions to be systematically tested and validated during the development phase.
Test Procedure and Execution
The HiL test begins with the preparation and configuration of the test environment. This involves defining the required vehicle models, communication interfaces, and test parameters, as well as integrating the control unit into the test setup.
During execution, defined test cases are run either automatically or manually. Various operating states, input signals, and error scenarios are simulated, and the control unit’s responses are continuously recorded.
Data Sources and Interfaces
In HiL testing, various data sources and interfaces are integrated to capture the behavior of the control unit and the simulated vehicle environment as comprehensively as possible. This generates both communication and measurement data, which are recorded and synchronized throughout the entire test sequence.
Typical data sources and interfaces are:
- CAN And CAN FD
- LIN
- FlexRay
Depending on the test setup, also:
- Automotive Ethernet
- Analog and digital signals
- RS-232
Combining these diverse data sources enables a holistic view of system behavior. Time-synchronized data acquisition facilitates the correlation of events and forms the basis for a reliable analysis and evaluation of the test results.
Data Logging Requirements
A HiL system connects real control units with a simulated vehicle environment. This process generates communication data from multiple vehicle networks as well as measurement data from the test bench equipment.
To ensure that test results can be evaluated reproducibly, all relevant data must be recorded synchronously.
Challenges in Test Operations
The operation of hardware-in-the-loop test systems places high demands on the acquisition, synchronization, and analysis of measurement and communication data.
Typical challenges include:
- Simultaneous recording of multiple communication networks
- Synchronization of communication and measurement data
- Reproducible test conditions
- Flexible adaptation to various HiL systems
- Analysis of complex control unit communication
Data Analysis and Further Processing
The measurement and communication data recorded during HiL testing form the basis for a detailed analysis of system behavior. By analyzing various data sources in a time-synchronized manner, it is possible to identify interrelationships, investigate specific faults, and evaluate test results. Subsequently, the data can be used for further analysis, automated evaluations, and reporting, as well as for the documentation and validation of vehicle functions.
Featured Product
XORAYA N16000
Precise data acquisition and analysis for hardware-in-the-loop testing
The XORAYA N16000 is a data sink used in applications such as complex hardware-in-the-loop (HiL) testing systems. It enables the centralized acquisition of large volumes of data at rates of up to 15 Gbit/s. By cascading the unit with additional XORAYA data loggers and probes, the system can be flexibly expanded to include the required interfaces and vehicle buses. A precise timestamp resolution of 100 ns and swappable storage units (RSUs) with capacities of up to 32 TB ensure reliable recording of extensive measurement data in demanding test bench environments.
Highlights
- Central hub for vehicle data collection
- Up to 15 Gbit/s recording speed
- Removable storage media with up to 32 TB
- Interface expansion via probes and data loggers
System examples
Which products do we recommend for HiL testing?
Selecting the right XORAYA products for HiL testing depends on the specific requirements of the test bench. Key factors include the required interfaces, data rates, number of measurement points, test duration, and existing infrastructure. Thanks to their complementary functions, XORAYA products can be seamlessly combined to create customized data logging solutions.
Single Data Logger
Individual ECUs or Components
- Data Logger: e.g., N4000
- Storage: e.g., ESU
- Software: e.g., Suite
Advanced System
Extended Signal Acquisition in Vehicles or on Test Benches
- Probes: e.g., MultiProbe X1
- Data Logger: e.g., N4000
- Data Storage Unit: e.g., ASU
- Software: e.g., Suite + App
Networked Data Loggers
Integrated Measurement System for Comprehensive Testing Processes
- Probes: e.g., MultiProbe X1 + Probe B12
- Data Logger: e.g., 2x N4000+
- Data Sink: e.g., 1x N16000
- Software: e.g., Suite + App
- SDK
Personal Consultation
Do you have questions about this product or a specific application? Our experts will be happy to provide you with personalized, no-obligation advice.
Services & Engineering
We provide the right measurement solution for your HiL test bench.
We develop customized system solutions based on our modular product portfolio – tailored precisely to your needs. By intelligently combining and adapting individual components, we create high-performance, scalable end-to-end systems from a single source – from planning through implementation.
Measurement System Design
We design scalable data logging systems tailored to your measurement requirements, with the appropriate interfaces, data rates, and storage capacities.
Vehicle & Test Bench Integration
We integrate your measurement equipment into test vehicles and test benches using tailored installation solutions and validate its functionality.
Cables & Wiring Harnesses
Custom-fit cable assemblies and wiring harnesses ensure signal quality, reliable power supply, and electromagnetic compatibility (EMC) in your specific installation.
Performance & Functionality
Targeted hardware and software modifications enhance our data loggers with additional performance, interfaces, and features.
Software Customization
Customer-specific software features extend the capabilities of our applications and support your individual measurement workflows.
Configuration & Support
From commissioning and user training to maintenance and repair, we provide support throughout the entire lifecycle of your measurement equipment.
FAQ
The following questions address key aspects of data acquisition and suitable logging systems for vehicle Hardware-in-the-Loop applications.
Why is Hardware-in-the-Loop used?
HiL enables reproducible testing of control units and system functions before they are deployed in a vehicle.
What data is recorded during a HiL test?
Typically, communication data from vehicle networks as well as measurement data from test bench technology and simulation systems.
What challenges arise during data logging?
The synchronous acquisition of multiple communication networks and the reproducibility of measurement data are among the most important requirements.
Which X2E system solution is suitable for Hardware-in-the-Loop?
The XORAYA N16000 serves as the central system component for complex measurement setups. Depending on the test setup, the data sink can be expanded with additional interfaces using components such as the XORAYA N4000+, Probe B12, or MultiProbe X1.
For smaller measurement systems, the XORAYA ASU offers an alternative solution that can also be flexibly combined with suitable probes and data loggers.
Which interfaces do X2E systems support for HiL applications?
Depending on the device configuration, X2E systems support CAN, CAN FD, CAN FD SIC, LIN, FlexRay, Automotive Ethernet (100BASE-T1 and 1000BASE-T1), Gigabit Ethernet, as well as analog and digital inputs and RS-232. Additional interfaces are available upon request.
Can X2E systems be connected to existing HiL test benches?
Yes. Depending on the test bench architecture, the modular systems can be expanded to include additional interfaces, probes, or storage solutions.
Which software functions support HiL tests?
Depending on the system, functions such as triggers, filters, live monitoring, and data export, as well as analysis and automation capabilities, are available.