SCALEXIO Power HIL – Low-Voltage

SCALEXIO Power HIL – Low-Voltage delivers precise emulation and dynamic testing for low-voltage components and systems up to 60 V. Ideal for electric power steering, mild hybrid drives, and auxiliary applications, it enables realistic current emulation and flexible integration, supporting advanced validation of e-mobility and industrial solutions.

Realistic Current Emulation

Model-based, highly dynamic emulation for accurate low-voltage testing.

Compact, Flexible Integration

Fits standard HIL cabinets and supports external components like climate chambers.

Scalable Power Extension

Multiple electronic loads in parallel deliver several kilowatts of power for flexible testing.

Safe Testing Environment

Integrated safety mechanisms protect devices and users during all test scenarios.

What is the SCALEXIO Power HIL – Low-Voltage?

SCALEXIO Power HIL – Low-Voltage is a flexible hardware-in-the-loop (HIL) system for testing and validating control units and components in low-voltage applications up to 60 V. It enables realistic emulation of key dynamic components across a wide range of applications, including e-mobility and industrial systems, helping engineers evaluate performance and reliability before hardware is available. The modular design supports scalable power and easy integration into existing setups, including environmental testing with climate chambers. With integrated safety features and upgradable architecture, SCALEXIO Power HIL – Low-Voltage optimizes development and enables realistic, safe, and efficient validation at the power level.

Application Areas

SCALEXIO Power HIL – Low-Voltage enables the validation of low-voltage components under realistic conditions. With its flexible design, the system supports a wide range of applications in industrial and mobility sectors, such as:

Electric power steering (EPS) and brake-by-wire systems
Starter and generator systems
Mild hybrid drives and auxiliary drive systems
E-bikes and e-scooters
Electric pumps
Electrically automated manual transmissions
Climate chamber testing for extreme environments
Industrial machinery and power tools
Electronic fuses
Electromechanical actuators

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Key Benefits

SCALEXIO Power HIL – Low-Voltage combines realistic low-voltage testing with the flexibility and scalability of modern HIL systems. Engineers can validate their control units and components under real-world conditions – efficiently and safely, even before hardware prototypes are available.

Highlights:

Realistic current emulation: Model-based, highly dynamic emulation for accurate and true-to-life low-voltage testing.
Easy simulation of variable motor inductances: Current-based emulation enables convenient testing of changing motor inductances without the need to exchange hardware components.
Flexible integration: Compact design fits seamlessly into standard HIL setups and supports external devices like climate chambers.
Scalable and modular: Parallel electronic loads enable higher power levels and easy system upgrades for future requirements.
Identical modeling environment: Consistent test environment for both signal-level and power-level tests, streamlining workflows and ensuring reliable results.
Safe and reliable operation: Built-in safety mechanisms protect devices and users during all test scenarios.
Support for discontinuous conduction mode: Enables emulation of sensorless brushless DC (BLDC) motors for advanced test scenarios.
Broad application range: Supports diverse low-voltage applications, from electric power steering and mild hybrid drives to industrial machinery and power tools.
Power recovery within the module: Integrated power recovery increases energy efficiency during testing.

Together, these benefits make SCALEXIO Power HIL – Low-Voltage the ideal solution for dynamic, future-proof validation of next-generation low-voltage systems.

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

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.