Power HIL

Power HIL: High‑Voltage Hardware‑in‑the‑Loop Testing by dSPACE

dSPACE’s Power Hardware‑in‑the‑Loop (Power HIL) systems redefine how power electronics and electric drives are validated. These turnkey, configurable platforms enable full‑power simulation of motor controllers, inverters, batteries, grids, and more—bridging the gap between traditional HIL testing and physical dynamometer setups.

What Is Power HIL and Why It Matters

At its core, Power HIL lets engineers test real hardware (like an inverter or charging controller) under genuine electrical loads—real currents and up to 1,250 V voltages—while simulating connected components such as motor or grid behavior. The platform offers a high-fidelity “digital twin” environment using real-time models, reducing the need for expensive prototypes.

This capability is invaluable early in development—before physical prototypes exist. Using dSPACE simulation models, functional behavior of components (motors, batteries, PV sources, smart grids) can be emulated and adjusted on the fly.

Flexible Voltage and Power: From Low‑Voltage to Megawatt Levels

Power HIL adapts to various application needs:

• High‑Voltage Systems using modules like the DS5386 electronic load, supporting up to 1,250 V and multiple MW power. Ideal for testing traction inverters, onboard chargers, renewable energy setups, aerospace propulsion, and industrial drives.
• Low‑Voltage Systems based on DS5380/DS5381 modules (up to 30–60 V), tailored for mild-hybrid drives, electric steering systems (EPS), auxiliary motors, and e‑scooter or e-bike applications.

The modular design lets multiple load modules be connected in parallel for higher power and flexible configuration. At the same time, system cabinets remain compact, lightweight, and easier to install than mechanical dyno test benches.

Core Benefits of Power HIL

Power HIL delivers multiple advantages:

• Turn‑key or modular hardware options, supporting wide voltage/power ranges and test concepts.
• Rapid controller validation early in the development cycle—no need for physical prototypes.
• Real-time, dynamic current-based emulation, including changing parameters like inductance or resistance during runtime.
• Test scenarios covering functionality, load conditions, edge cases, and compliance with standards such as LV123 or ISO/DIS 21498.
• Reduced risk and no moving parts, improving safety and minimizing mechanical downtime or damage.

Seamless Integration with Simulink & ASM Models

dSPACE leverages a unified development ecosystem:

• Real-time simulation models using SCALEXIO systems (CPU + FPGA) run on dSPACE’s generic hardware.
• Open models for motors and encoders (XSG library), batteries (Automotive Simulation Models, ASM), and entire grid topologies (Electrical Power Systems Simulation package) are supported.

This enables users to configure test benches with “just a few clicks,” drastically reducing setup time and facilitating flexible repeats and system scaling.

Real-World Use Cases

Automotive traction inverters: Validate inverter control logic during real current draw, including robustness tests under transient and fault conditions.

Onboard chargers & EV charging stations: Emulate both grid and vehicle-side loads to ensure compliance with communication protocols like ISO 15118 or CHAdeMO.

Renewable energy and microgrids: Assess interactions between distributed resources, smart grid controllers, V2G scenarios, and more—capturing fluctuations in power flow in real time.

Power HIL Compared to Conventional Testing

Power HIL closes the gap between electronic simulation and physical testing—offering true high-power validation before real systems exist.

Why Choose dSPACE’s Power HIL

• Full range power support, from low-voltage controllers to multi-megawatt motor drive systems.
• Seamless integration into dSPACE’s software and hardware ecosystem.
• Advanced component emulation, including parameter manipulation during runtime.
• Turnkey or modular test benches with fast setup, and flexible system upgrades.

Whether you are designing for powertrains, EV chargers, renewable energy systems, or aerospace applications, Power HIL provides a comprehensive platform for robust validation and accelerated time-to-market.

In Summary

Power HIL by dSPACE empowers engineers to perform real-time, power-level HIL testing with real currents and voltages—emulating complex power systems without physical prototypes. With modular hardware, rapid setup, real-time models, and compliance-ready test cases, this technology significantly enhances confidence, accuracy, and speed in power electronics testing workflows.

For developers working on electric drives, microgrids, V2G, or industrial power electronics, dSPACE Power HIL offers unmatched flexibility and realism—right when you need it most.