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Hardware-in-the-loop (HIL) testing is an indispensable tool in the software development process for electronic control units (ECUs) and Logical Replaceable Units (LRUs) and is an integral part of the software validation process for many organizations. HIL simulation is regarded as the tried-and-tested method for function, component, integration and network tests for the entire system. Using the Model based design approach has further enabled improved and faster HIL implementations in recent years. This paper describes the changing requirements for HIL simulation, and how they need to be addressed by HIL technology. It also addresses the challenges faced while setting up a successful HIL system: namely the division of tasks, the total cost of ownership, budget constraints and tough competition and the adaptability of a HIL simulator to new demands. These requirements are discussed using a dSPACE HIL system architecture that was designed from the ground-up to address these needs.

To make the development of complex aircraft systems manageable and economical, tests must be performed as early as possible in the development process. The test goals are already set in advance before the first hardware for the ECUs exists, to be able to make statements about the system functions or possible malfunctions. This paper describes the requirements on and solutions for test systems for ECUs that arise from these goals. It especially focuses on how a seamless workflow and consistent use of test systems and necessary software tools can be achieved, from the virtual test of ECUs, which exist only as models, up to the test of real hardware. This will be shown in connection with a scalable, fully software-configurable hardware-in-the-loop (HIL) technology. The paper also covers the seamless use of software tools that are required for HIL testing throughout the different test phases, enabling the reuse of work products throughout the test phases.

Hardware-in-the-loop (HIL) simulation is now a standard component in the vehicle development process as a method for testing electronic control unit (ECU) software. HIL simulation is used for all aspects of development, naturally including safety-relevant functions and systems. This applies to all test tasks (from function testing to release tests, testing a single ECU or an ECU network, and so on) and also to different vehicle domains: The drivetrain, vehicle dynamics, driver assistance systems, interior/comfort systems and infotainment are all tested by HIL simulation. At the same time, modern vehicles feature more and more safety-related systems such as Adaptive Cruise Control, Electronic Stability Program, Power Assisted Steering, and Integrated Chassis Management.