Traction converters power electric vehicles, trains, ships, and aircraft—where safety, performance, and reliability are non-negotiable. RTSim’s real-time HIL simulation connects actual traction controllers to high-fidelity digital models of the powertrain, enabling exhaustive testing under realistic and hazardous conditions.

This approach supports rapid development, fault resilience, and system optimization across automotive, railway, marine, and aerospace industries.

Solution Benefits

  • Embedded Software Validation Test control loops, startup sequences, and safety interlocks without physical motors or vehicles.
  • Multi-Motor Coordination Validate synchronization and torque sharing across multiple drive units.
  • Real-Time Simulation Fidelity Sub-microsecond time steps capture fast switching and transient behavior.
  • Reduced Development Risk Identify integration issues and edge cases early in the development cycle.
  • Compliance & Performance Testing Validate against standards for efficiency, safety, and electromagnetic compatibility (EMC).
  • Cyber-Physical Resilience Simulate communication loss, spoofing, and degraded modes to assess system robustness.

Hardware-in-the-Loop (HIL) testing of Traction Converter

HIL simulation connects the real traction converter controller to a real-time digital twin of the motor, drivetrain, and electrical network in RTSim, enabling closed-loop testing of control logic, switching behavior, and safety functions under realistic conditions.

PWM & Gate Signal Capture

  • The controller’s PWM outputs are captured by RTSim to drive the virtual inverter and motor model.
  • Enables validation of modulation strategies, current control, and switching dynamics.

Analog & Digital I/O

  • Simulated feedback signals (e.g., motor currents, voltages, temperatures, speed) in RTSim are fed into the controller.
  • Control outputs (e.g., enable signals, fault flags) are captured in RTSim to update the simulation state.

Encoder & Resolver Emulation

  • Simulate position feedback devices in RTSim ato test sensor-based control algorithms like field-oriented control (FOC).
  • Supports validation of startup logic, speed estimation, and torque control.

Load & Environment Modeling

  • Emulate mechanical loads, gradients, wheel slip, and regenerative braking in RTSim to test drive response.
  • Includes traction effort, adhesion limits, and multi-axle coordination.

Communication Protocols

  • Support for CAN, Ethernet, and proprietary vehicle bus protocols in RTSim for diagnostics, control, and telemetry.
  • Enables integration with vehicle control units (VCUs) and supervisory systems.

Fault Injection & Safety Testing

  • Simulate overcurrent, undervoltage, thermal overload, and sensor failures in RTSim realistically.
  • Validate fault detection, isolation, and recovery logic in real time.

Why It Matters

  • Accelerates propulsion system development by enabling safe, repeatable testing without full-scale mechanical setups
  • Improves control reliability through closed-loop validation of torque, speed, and regenerative braking logic
  • Reduces hardware dependency by replacing dynamometers and test tracks with real-time simulation
  • Supports multi-axle coordination for rail, EV, and industrial mobility platforms
  • Enhances safety and fault resilience by simulating overcurrent, sensor failures, and degraded modes
  • Validates embedded software and startup sequences under realistic load and gradient conditions
  • Enables protocol-level testing for CAN, Ethernet, and proprietary vehicle bus communications
  • Facilitates compliance and performance tuning for traction effort, efficiency, and thermal limits

Design and validate high-power traction systems with RTSim. Safer testing, faster results.