SCALEXIO Power HIL – High-Voltage

SCALEXIO Power HIL – High-Voltage enables dynamic testing of control units with integrated power electronics up to 1,250 V. Taking real-time simulation to the power level provides a flexible environment for validating all types of inverters and converters – even for demanding conformance tests. The behavior of machines, grids, and batteries can be emulated at full power, ensuring realistic conditions for safe and efficient development.

Full-Power Testing

Test with real currents and at full power in a safe environment.

Flexible Emulation

Emulate motors, batteries, and power grids with the same hardware.

Modular Scalability

Customize system power and emulated functions to your needs, even after deployment.

Investment Protection

Reduce development and testing costs through modular, reusable hardware.

What is the SCALEXIO Power HIL – High-Voltage?

SCALEXIO Power HIL – High-Voltage is a modular hardware-in-the-loop (HIL) system for validating power electronics devices in high-voltage applications up to 1,250 V. It combines the flexibility of real-time simulation with testing under realistic, dynamic load conditions. This approach enables efficient and reproducible test scenarios in a virtual environment – even before physical prototypes are available. The system is specifically designed to validate inverters and converters, including both controllers and power electronics, under realistic operating conditions. Its modular design supports turnkey and customized setups, enabling easy adaptation to different use cases and power levels.

Application Areas

SCALEXIO Power HIL – High-Voltage enables full-power testing of high-voltage components across a wide range of industries by emulating electric motors, batteries, and grids under realistic conditions. Typical application areas include:

Traction inverters for electric drives
DC/DC converters
Photovoltaic and wind inverters
Charging stations and onboard chargers
Electric aircraft propulsion systems
High-performance industrial drives

This sounds interesting. Get in touch:

Contact

Key Benefits

SCALEXIO Power HIL – High-Voltage combines full-power testing with the flexibility of modern HIL systems. This allows you to validate devices under realistic, full-power load conditions while instantly adjusting the behavior of the environment with just a few clicks.

Highlights:

Module-based design: Expand system power or add modules at any time for future needs.
Open machine models: Adapt models, even beyond parameter changes, for maximum flexibility.
Seamless continuity: Consistent models and workflows across all test levels, from SIL to HIL to power HIL.
High-precision emulation: Achieve outstanding accuracy with highly dynamic modules and FPGA-based control.
Energy efficiency: Circulating power flow minimizes grid load, requiring less than 15% of emulation power.
Turnkey solution: Hardware, software, support, and integration from a single source for fast deployment.
Investment protection: Reuse hardware and models for new projects, reducing long-term costs.
Safe virtual environment: No moving parts.
Conformance and failure testing: Supports ISO 21498 and LV 123 and enables comprehensive fault and conformance testing.

Together, these capabilities make SCALEXIO Power HIL – High-Voltage the ideal solution for engineers seeking a future-proof, high-performance emulator, that supports machine, grid, battery, and electric load emulation in demanding high-voltage environments.

Be Inspired by the Capabilities of SCALEXIO Power HIL – High-Voltage

Unique Modular Hardware Approach

The transition from behavior simulated in real-time models to real hardware devices is realized through DS5386 High-Voltage Electronic Load Modules.

Each module is controlled decentrally and emulates a single function, such as:

A machine phase
A grid phase
The positive or negative pole of a battery

By connecting multiple modules in parallel, the power rating of each function can be scaled as required. Thanks to this modular concept, the test bench can be precisely configured for the required number of interfaces to be emulated and the overall system power, and easily expanded later.

System Software

Real-time models are the core of SCALEXIO Power HIL test benches and determine the electrical behavior at the power interfaces.

dSPACE provides both processor-based and FPGA-based models for machine and battery emulation at various levels of detail. These models can include nonlinearities and transient behavior and can be customized. Thanks to an open model approach, not only parameterization but also structural changes to the models are possible.

Model parameters can even be adjusted during run time via ControlDesk, the dSPACE experiment software for ECU development.