A hardware-in-the-loop test stand (HiL test stand) from TMX gives your device under test a virtual but fully realistic environment. You can test critical components without the real surroundings having to exist yet. Our HiL test stands combine clever mechanics with open software interfaces and modular, high-quality measurement technology. We integrate established standard tools and keep the system flexible, which saves time and money and makes development more effective and more reliable.
HiL test stands belong to the custom test systems from TMX and allow hardware-in-the-loop testing early in development.
A hardware-in-the-loop test stand (HiL test stand) tests components and systems under realistic conditions before they are integrated into their final environment. The device under test behaves as if it were already part of the complete system, because it is exposed to exactly the same physical and electronic influences.
Typical simulations in a HiL test are residual bus simulation (replacing the missing field or vehicle bus), environmental simulation (heat, cold, humidity and so on) and load profile simulation (realistic mechanical loads).
Mechanical loads include forces, torques, temperatures, pressures, speeds, accelerations and vibration. The software and firmware environment matters just as much, above all communication with control units over bus systems such as CAN or LIN, as used in modern vehicles.
Combining physical and digital influences creates a test environment in which the device under test "believes" it is already in its final application. The result: meaningful data and a faster development process.
An electric window lifter is a good example of how a HiL test stand works. Designs vary; a common one uses an electric motor driving a cable drum through a worm or spur gear. Depending on the direction of rotation, the window opens or closes.
Friction changes along the window travel. In the middle section the rubber seals keep friction largely constant; at the end positions it rises sharply because of the window curvature and the mechanical end stop. A HiL test stand has to reproduce these loads with precise real-time control.
A meaningful HiL test needs realistic environmental conditions: window lifters in vehicle doors have to withstand temperatures from -40 °C in winter to over 100 °C in summer. Direct sunlight heats the door considerably, and the motor absorbs much of that heat.
In the vehicle, the window is operated by switches in the door, while a control unit handles the actual control over the vehicle bus (CAN or LIN). The same unit coordinates comfort functions (automatic open and close, synchronization with central locking), safety functions (anti-pinch protection) and fault detection. For HiL testing you either need the original control unit, or the HiL test stand takes over this communication through residual bus simulation.
🔹 Simulation of the target environment 🔹
Early validation without the physical complete system
🔹 Dynamic load simulation and real-time control 🔹
Realistic mechanical and electrical load scenarios
🔹 Residual bus simulation and communication interfaces 🔹
Simulate control units and communication signals over CAN, LIN, Ethernet and more
🔹 Environmental simulation 🔹
Test influences such as temperature, humidity and aging
🔹Automotive and commercial vehicles🔹
HiL tests of headlamps, window lifters, gearboxes and motors
🔹Aerospace🔹
Autopilot and flight dynamics tests in virtual environments
🔹Energy🔹
Validation of power electronics, battery systems and inverters
🔹Industrial automation and robotics🔹
Validation of machine and plant controllers
THE SOLUTION
A TMX HiL test stand gives you a complete test environment in which physical and software conditions are simulated realistically. Physical parameters such as temperature, forces and torques are controlled precisely using proven tools such as MATLAB/Simulink. At the same time the software environment is reproduced: bus communication (e.g. with Vector tools) and control unit integration (with tools such as INCA or dSPACE). This lets you test and optimize machine and vehicle components before they go into the real world.
Questions? Talk to us.
The mechanics of a TMX HiL test stand are designed for the real load scenarios of the device under test. For a window lifter motor test stand, for example, a travel-dependent torque profile is reproduced with a combination of adapter mechanics, brake and guided carriage, including safe temperature control in a climate chamber. A high-quality torque transducer captures torque and angle, while stable carriage systems provide a uniform base load. Eddy current brakes reproduce the load profiles found in the vehicle, so all mechanical loads are simulated realistically.
Our HiL test stands use capable measurement, control and closed-loop technology that handles complex tasks in real time. Signal processors compute directly on the incoming data streams for authentic behavior. Programming in vendor-specific languages or in C/C++ adapts the system to the task. Open interfaces connect to control and modeling environments such as MATLAB, so you can implement your own control algorithms. Residual bus simulation environments connect through a range of interfaces and implementations.
The TMX software is the heart of a modern HiL test stand: powerful and easy to extend. It integrates external systems for modeling and simulation. Residual bus simulation often plays a central role and goes far beyond sending a few CAN messages; in many cases the customer or the manufacturer of the DUT provides it, because it contains proprietary information embedded in the control unit firmware. TMX supports industry standards such as Vector, dSPACE and INCA. Environmental simulation, different data formats from various subsystems and extensive online math functions are part of the scope. Engineers value the many ways to intervene in control parameters and optimization processes, for example to analyze frequency responses or step responses. A clear, freely configurable user interface brings all relevant data together for efficient evaluation.
WHY TMX
Our HiL test stands enable highly realistic testing, even when the final complete system does not exist yet. Mature control technology, flexible integration and well-engineered mechanics create a test platform that simulates real conditions: reliable, efficient and adaptable.
20+ years of test stand engineering and a strong network of specialists
Precise load profiles with highly dynamic real-time control, e.g. for travel-dependent torque simulation
Many clever solutions for temperature and climate chamber feedthroughs under real environmental conditions
Proven solutions for residual bus simulation and realistic vehicle environments
Adaptable interface and support for many industry standards for efficient, expandable test processes
Discover the technology behind TMX HiL test stands and what sets it apart.
Which HiL tests need to be covered? Which technical conditions apply? We define the requirements together and develop a test stand concept that fits.
Mechanics, controls, measurement technology, software: we combine proven industry standards with new ideas for a system that performs now and later.
We build and assemble your test stand and integrate the software, with accuracy in every detail and a modular architecture for future extensions.
We run the first tests, fine-tune the system and validate the test stand under realistic conditions.
Thorough training and complete technical documentation get your team up to speed. Maintenance and support keep the system running for years.
Every test environment has its own requirements, so we build custom solutions. Our hardware-in-the-loop test stands are used for a wide range of applications, including:
YOUR NEXT STEP
We advise you on HiL testing and HiL test stands and find the right solution for your requirements. Contact us for a no-obligation consultation or a quick price estimate.
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