SCALEXIO Customized System

Application-ready HIL system

The dSPACE SCALEXIO customized system is a highly versatile hardware-in-the-loop simulator that offers a comprehensive range of adaption and configuration options to meet customer-specific requirements. It is scalable from small to large systems and can be used flexibly from components testing to simulating complete virtual vehicles.

Application Areas

The SCALEXIO customized system is usually installed in one or more 19” cabinets. Its height can be tailored to your requirements. The system can be used for any application, including complex simulations of a complete virtual vehicle.

Typical fields of application include:

  • Autonomous driving
  • Electromobility
    • Electric motor simulation for hybrid or electric powertrains and electric steering systems
    • Battery management systems
    • Electric motor emulation at power level (power hardware-in-the-loop) or high-voltage capable for battery management testing
  • Engine, powertrain, chassis, and body
  • Truck applications (24 V/36 V)
  • Racing applications (Formula One, Ralley)
  • Mechanical test benches
  • Comprehensive closed-loop testing on ECUs, release/acceptance tests
  • Networked ECUs
  • Special requirements, e.g., for high system flexibility and high-current or high-voltage applications

Key Benefits

The SCALEXIO customized system utilizes a highly scalable,  modular rack concept that is flexible and open enough to meet any of your requirements. The I/O hardware offers extensive I/O features and is largely software-configurable, which facilitates adapting the system to changing project requirements. Adapted to your specific application and requirements, the system is fully commissioned, documented, quality-assured and put into operation directly at the customer’s site. This way, it is ready for operational use right from the time of delivery. Adaptations and extensions are possible whenever required.

Coupling Options

To increase your computational power and available I/O interfaces, you can interconnect as many SCALEXIO customized systems as needed. If the project requirements change, you can easily adapt your testing system. Coupling SCALEXIO systems is done via IOCNET.

All software for configuring the system and controlling the simulation or test automation runs on a host PC. The PC is connected via Ethernet with the SCALEXIO system.

Fault Simulation

For fault simulation, the SCALEXIO rack system provides I/O boards with integrated fault simulation, namely the HighFlex boards (DS2601, DS2621, DS2642, and DS2671) and MultiCompact I/O Units (DS2680 and DS2690).  

Comprehensive Customization Options

  • Maximum flexibility thanks to a modular concept
  • Minimal hardware modifications needed if requirements change
  • All signals accessible on terminal stripes for additional measurement tasks and for a flexible response to changing specifications
  • Clear and transparent system architecture
  • Multirack systems possible

Flexible, Modular Hardware

  • Single-processor or multiprocessor system for high computation requirements
  • Freely expandable with any SCALEXIO board according to project needs
  • Expandable, e.g., with hardware for fault insertion and load simulation (customer-specific configuration)
  • Expandable, e.g., with flexible FPGA boards

Signal Conditioning

  • Signal conditioning included with SCALEXIO MultiCompact I/O and SCALEXIO HighFlex hardware
  • Support of almost any signal type, e.g., digital in/out, analog in/out, relay simulation, current sink/source, LVT simulation, resistance simulation, and linear lambda probe simulation
  • Additional modules on request

Simulation of Linear Lambda Probes

LSU (Lambda Sonde Universal, universal lambda probe) is a signal conditioning module that simulates the behavior of linear lambda probes. These probes measure the air-fuel ratio in a car’s exhaust system. The engine ECU reacts by varying the injection time, so the catalytic converter can operate at an optimal performance rate.

The LSU module allows for generating Nernst cell voltage on four independent channels based on pump current and Nernst cell inner resistance. The module functions as a linear probe or as a jump probe. Parameters such as maximum/minimum Nernst cell voltage can be adjusted.

Load Capabilities

  • Modular load concept with customer-specific configuration
  • Support of single-ended and double-ended loads
  • Resistive loads or other kinds of equivalent loads
  • Connection of electrically equivalent loads or low-power resistive loads
  • Connection of real loads, optional rack integration
  • Integration of customer's load panels
  • High-speed electronic loads, e.g., simulation of electric machines
  • Connection to high-voltage emulation systems and test benches

Programmable Power Supplies

The programmable power supply unit feeds the components to be tested and allows for simulating real voltages such as a vehicle’s battery voltage during start-up. The power supply unit is remotely controlled from within the real-time model.

Various power supplies are available for different applications, for example:

  • 0 ... 20 V
  • 0 ... 60 V

Hardware and Software for SCALEXIO Customized System

You can use all SCALEXIO boards in the SCALEXIO Customized Systems along with a wide range of dSPACE software to configure settings and implement models, among other things.

SCALEXIO Processing Unit Product lines for high core performance and high parallel performance ConfigurationDesk Configuration and implementation software for dSPACE real-time hardware DS6101 Multi-I/O Board SCALEXIO I/O board with signal conditioning for automotive systems DS6201 Digital I/O Board SCALEXIO I/O board with 96 bidirectional digital I/O channels DS6221 A/D Board Fast SCALEXIO A/D Board for precise measurements DS6241 D/A Board Multi-channel D/A board DS2655 FPGA Base Board SCALEXIO I/O board with user-programmable FPGA DS6301 CAN/LIN Board SCALEXIO I/O board for connecting simulators to CAN/CAN FD and LIN bus systems DS6331-PE Ethernet Board The DS6331 provides additional Ethernet ports for the SCALEXIO Processing Unit DS2601 Signal Measurement Board HighFlex board for measuring ECU output signals DS2621 Signal Generation Board HighFlex board for simulating ECU input signals DS2642 FIU & Power Switch Board HighFlex board for power-switching with Failure Insertion Unit DS2671 Bus Board HighFlex board for connecting to different bus systems DS2680 I/O Unit SCALEXIO MultiCompact unit for powertrain and vehicle dynamics scenarios DS2690 Digital I/O Board MultiCompact I/O board for vehicle body scenarios DS2907 Battery Simulation Controller SCALEXIO power supply control for battery simulation Electrical Power Systems Simulation Package Easy real-time simulation of power electronics circuits developed with Simscape Electrical™ (Specialized Power Systems) EMH Solution for SCALEXIO Processor based simulation of electric drives SCALEXIO Serial Interface Solution Using Serial Peripheral Interface (SPI) and Inter-Integrated Circuit (I2C) bus SCALEXIO TWINsync Solution Synchronous load motor control for test benches with dSPACE SCALEXIO SCALEXIO Fieldbus Solution Connecting a SCALEXIO system to various fieldbus types Bus Manager Configuration tool for LIN, CAN, and CAN FD bus simulation
Product Information

Subscribe newsletter

Subscribe to our newsletters, or manage or delete your subscriptions