Hardware-in-the-Loop

Realistic testing of next-generation electromobility systems using BeXema Hardware-in-the-Loop emulators

Our Hardware-in-the-Loop (HiL) simulators enable the emulation-based representation of complex electrical systems such as batteries, fuel cells, electrolyzers, and AC networks under realistic operating conditions—without the need for physical power hardware. The emulators digitally reproduce dynamic system behavior in real time and provide well-defined electrical interfaces for testing control units and power electronics. 

By virtualizing the devices under test, development times can be significantly reduced, costs for prototypes and test setups lowered, and test results ensured to be reproducible. High flexibility in test scenario parameterization, short reconfiguration times, and precise measurement and control capabilities substantially increase the efficiency of development and validation processes. Functions and operating strategies can be verified at an early stage, and potential risks can be systematically identified. 

Hardware-in-the-Loop systems from BeXema support accelerated system development, reduce testing effort, and improve the reliability and quality of test results. 

Technical Specifications
Our HIL emulators offer the following features:

• Voltages up to 0 – 1,500V
• Currents up to ±20kA
• Comprehensive operating modes (U, I, P)
• Short settling time <1ms
• Galvanic isolation from the power grid
• Insulation monitoring (ground fault detection)
• Operation via system controller with touch display
• Integrated battery models
• Highly dynamic and precise voltage regulation
• Active current limitation
• Parallel operation of multiple HIL emulators possible (master-slave)
• Easy test bench integration via Ethernet and CAN (10kHz for hybrid integration). Additional interfaces available upon request.
• Device safety in accordance with ISO 13849-1