In HIL test systems, cars can be test braked before they exist
At Together Tech, we are passionate about challenges. They can be technology-related, schedules that seem impossible, solutions that must fit within tight cost limits, or product development where others have taken a bite.
With today's rapid technological development in various industries, there are plenty of challenges. An example is within Automotive, which has a rapidly growing need to carry out virtual instead of physical tests of electronic control units. This is done, among other things, with Hardware-In-The-Loop (HIL) test systems.
Electrification, continuous innovation, lots of electronics and ever shorter time from idea to market launch place new demands on the automotive industry's test applications. More and more tests are moving from physical test cells to virtual testing in HIL test systems. Together Tech has developed complete HIL test systems for commercial vehicles. We also have many years of experience in developing test systems and test rigs for construction and verification tests. In this article, we want to focus on HIL, which is an exciting sub-area within testing. It will be extra exciting when more industries take the step over to HIL simulation.
More industries than Automotive HIL simulates
For Automotive there are figures that show the need for HIL. Today, electronics account for approximately 40 percent of a car's total cost. By 2030, it may have increased to 45 percent. In new cars, there can be more than a hundred electronic units for, for example, steering, comfort, brakes and many other safety functions. By the time an automotive engine becomes available for final testing, as much as 95 percent of engine control unit testing may have been completed using HIL simulation. The complexity and number of control units is constantly growing, which means that the test needs increase.
Virtual test environments and HIL simulation have been around for many years, but the use of HIL has broadened into new industries and this is a development that will continue. When developing sterilization machines for healthcare, HIL testing provides large energy and water savings during the development phase. Radar systems can be evaluated, and the amount of flights reduced (good for the environment!), when radar targets are simulated with HIL. In the development of pilot functions in aircraft, HIL test systems are used to simulate human factors and behaviors. In recent years, HIL has also started to be used to verify the stability and fault tolerance of large-scale power grids.
Ultra-fast delivery of two test rigs
In other words, the need for HIL test systems is great and getting bigger all the time.
- Our main focus today is on Automotive, but we monitor developments in other market segments. The overall concept we have for new development and upgrading of test rigs can be applied to other areas and we see a very large potential for our offer within HIL. We are a strong and complete HIL partner and we have also shown that in the assignments we have had in the automotive industry, says Mikael Duvander, Business Unit Manager and CQO at Together Tech.
In 2021, Together Tech was commissioned to upgrade an older HIL test system for heavier vehicles. Old components would be replaced with new ones and the system would also get new functionality. By upgrading the system architecture, they also wanted to make HIL more flexible and easier to configure. The assignment was then followed by an order for two completely new test rigs. This project started towards the end of 2022 and the test rigs were delivered to the customer in 2023.
- This is more than a fast project within HIL when it comes to producing new test rigs, it is ultra fast. Normally, such projects take considerably longer. This capacity is a strength and it is important because the development times within, for example, Automotive are getting tighter, says Mikael.
With us there is no "it doesn't work"
To enjoy challenges, one must be stubborn. Never give up, constantly search for new opportunities and solutions where others see severe obstacles. One of the tenacious people at Together Tech is Marko Koivumäki, Business Unit Manager with a focus on Mechanical Engineering and Embedded Systems.
- In many projects we have found solutions where others have failed. The fact that we don't give up is something of a hallmark for us and reasoning "it doesn't work" is never relevant. I also think we are a bit unique in terms of the ability to customize test concepts when standard solutions are not enough. Our ambition also extends wider than the purely technical. The fact that we offer training and place great emphasis on the design of documentation and user manuals for the test rigs is important and valued by our customers, says Marko.
Good component selection creates important customer values
Sustainability is a high priority for Together Tech and also guides us in the work of developing test rigs. This applies, among other things, to the choice of components. In recent years, component shortages have become a reality that we also have to take into account in our product development. Still, we always find ways to good component choices.
By designing hardware where components can be more easily replaced and upgraded, the lifespan of the test rigs is extended while making updates easier.
For industries where technology and product development is extremely fast, our design of test rigs can create important customer values. Our customers in Automotive know that and our ambition is to eventually also help companies in other industries that need HIL test systems.
Integrity and responsibility
Our resources and broad competence are a security for our customers. We like to take total responsibility and when developing and modernizing test rigs, this means, among other things, that we;
- Take total responsibility for the entire development and manufacturing process up to delivery and commissioning of complete test rigs
- Manage projects during all parts of the process
- Contribute with all necessary competence in electronics, mechanics and software development
- Evaluate and selects production partners and subcontractors
- Upgrade existing test rigs
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