Description:HARDWARE-IN-LOOP (HIL) TESTING SYSTEM

FIELD OF THE DISCLOSURE
[0001] This invention generally relates to the field of automotive technology, and in particular relates to a hardware-in-the-loop (HIL) testing system for a vehicle.

BACKGROUND
[0002] The subject matter discussed in the background section should not be assumed to be prior art merely as a result of its mention in the background section. Similarly, a problem mentioned in the background section or associated with the subject matter of the background section should not be assumed to have been previously recognized in the prior art. The subject matter in the background section merely represents different approaches, which in and of themselves may also correspond to implementations of the claimed technology.
[0003] Vehicles are a critical part of the shift towards sustainable transportation, but testing the vehicle’s complex systems such as powertrains, battery management, and thermal controls poses significant challenges. Traditional testing methods, which rely on physical prototypes, are costly, time-consuming, and often limited in scope. To overcome the limitations of the traditional testing methods, Hardware-in-the-Loop (HIL) testing has emerged as a preferred approach, allowing real hardware to interact with simulated environments. The HIL testing method reduces risks, lowers costs, and speeds up development by replicating real-world scenarios without requiring complete physical setups.
[0004] Despite the advantages of the HIL testing, HIL testing systems face several challenges. High initial costs, complex setups, and limited model accuracy make adoption difficult, especially for smaller organizations. Integration issues with proprietary protocols and custom hardware add to the complexity, while frequent updates increase maintenance costs and downtime. Additionally, the HIL testing systems require specialized expertise, limiting their accessibility.
[0005] According to a patent application “CN101109789B” titled as “Intelligent analyzing test bench for performance of electric car storage battery” which discloses an intelligent performance analysis and testing bench for batteries of motorized automobiles, which allows the studying and analysis on the charging and discharging characteristics of various batteries in a lab, so as to reduce the studying cost, shorten the studying time, simplify the studying procedures and improve the analysis accuracy. The invention comprises a main system interface module comprising a hi-voltage charging parameter setting module and a hi-voltage charging display module. The hi-voltage charging comprises hi-voltage programmed charging and hi-voltage constant-current charging. The main system interface module additionally comprises a low-voltage charging parameter setting module and a low-voltage charging display module. The low-voltage charging comprises low-voltage programmed charging and low-voltage constant-current charging. The main system interface module additionally comprises a discharging parameter setting module and a discharging display module. The charging comprises programmed discharging and constant-current discharging .
[0006] According to another patent application “CN115753141A” titled as “Universal simulation test platform and method for energy storage component of electric automobile” disclosed a general simulation test platform and method for an energy storage component of an electric automobile, wherein the platform comprises the following components: the system comprises a high-voltage power distribution cabinet, a charging and discharging test power supply, a whole vehicle real-time simulation system, an energy storage system to be tested and an upper computer; the high-voltage power distribution cabinet and the charging and discharging test power supply are compatible with various electric automobiles; the finished automobile real-time simulation system comprises a driver model, a finished automobile control model and a finished automobile model; during testing, the driver model and the whole vehicle control model can be replaced by real objects, and the energy storage component in the whole vehicle model is replaced by an energy storage system to be tested; the upper computer is connected with the CAN bus to acquire other part information in the platform, control the information and monitor and collect test data. The invention can carry out simulation test on the energy storage systems of the electric automobiles with different configurations and the control algorithms thereof, and the real components are accessed into the simulation environment under different systems or test modes, thereby effectively shortening the research and development period, supporting the test under extreme working conditions and avoiding the potential danger of the test of the real automobiles.
[0007] However, the present inventions do not disclose simulating load condition of the vehicle explicitly. The present inventions also do not disclose reducing battery assembly and dis-assembly time. To address these challenges, a solution is needed that reduces the HIL testing costs, simplifies setup and integration, improves simulation accuracy, and minimizes the need for specialized expertise.
OBJECTIVES OF THE INVENTION
[0008] The objective of present invention is to provide a cost-effective hardware-in-the-loop (HIL) testing system and method that reduces dependency on expensive proprietary hardware while ensuring robust evaluation of vehicle systems.
[0009] Further, the objective of present invention is to develop a customized and scalable HIL testing setup that leverages the vehicle's existing control unit (VCU) and I/O interfaces for real-time testing and validation of automotive subsystems.
[0010] Furthermore, the objective of the present invention is to create a versatile simulation framework using widely available software tools like MATLAB/Simulink for developing, deploying, and refining vehicle models.
[0011] Furthermore, the objective of the present invention is to facilitate the testing of complex vehicle subsystems such as powertrain, battery management, and thermal management under a range of real-world and fault-injection scenarios.
[0012] Furthermore, the objective of the present invention is to ensure seamless integration and communication between virtual vehicle models and physical components through standardized interfaces like CAN, LIN, and analog/digital I/O.
[0013] Furthermore, the objective of the present invention is to enable rapid prototyping, iterative testing, and efficient validation of vehicle systems during the development cycle.
[0014] Furthermore, the objective of the present invention is to provide comprehensive logging and analysis of test data to validate system performance and identify issues efficiently.
[0015] Furthermore, the objective of the present invention is to ensure the setup remains adaptable for future expansions, including advanced testing for emerging vehicle technologies and system upgrades.
SUMMARY
[0016] The present invention relates to a hardware-in-loop (HIL) testing system for a vehicle.
[0017] According to an aspect, the present embodiments discloses a hardware-in-loop (HIL) testing system for a vehicle comprising. a plurality of testing chambers each comprising one or more input/output (I/O) interfaces configured to establish communication with at least one component of the vehicle under test through the plurality of testing chambers, a memory device stored with one or more databases each having a vehicle simulation model. Further, the vehicle simulation model comprises one or more operating conditions of the vehicle and one or more environmental conditions, at least one processor communicatively coupled with the memory device and the plurality of testing chambers through the one or more input/output (I/O) interfaces. Further, the at least one processor is configured to provide one or more fixed input signals and one or more dynamic input signals to the at least one components through the one or more input/output (I/O) interfaces. Further, the one or more fixed input signals and one or more dynamic input signals are generated by the vehicle simulation model, receive one or more output signals generated by the at least one component in response to the one or more fixed input signals and the one or more dynamic input signals, analyse the one or more output signals, and generate at least one report having the response of the at least one component
[0018] In some embodiments, the plurality of testing chambers further comprises at least a powertrain, a battery management unit, a thermal management unit, and a control unit.
[0019] In some embodiments, the HIL testing system further comprising one or more testing equipment communicatively coupled to the one or more I/O interfaces. Further, the one or more testing equipment comprises at least one of signal conditioners, power supplies, and load simulators.
[0020] In some embodiments, the signal conditioners are configured to process the one or more fixed input signals and one or more dynamic input signals, and wherein the power supplies are configured to provide electrical power to the at least one component of the vehicle during real-time testing, and wherein the load simulators are configured to emulate electrical loads.
[0021] In some embodiments, the one or more I/O interfaces comprises analog interfaces, digital interfaces, and communication interfaces.
[0022] In some embodiments, the one or more operating conditions, comprises real-world driving conditions, fault injection scenarios, and environmental variations, wherein the one or more predefined environmental conditions comprises temperature, humidity, vibrations, and moisture.
[0023] In some embodiments, the at least one processor is further configured to validate the at least one component of the vehicle under test by performing the real-time testing of the at least one component in isolation, injecting test signals to emulate the one or more predefined operating conditions, and processing drive cycle data to simulate real-time load demand.
[0024] In some embodiments, the at least one processor is further configured to verify real-time the execution of the deployed vehicle simulation model without delays or jitter.
[0025] In some embodiments, the at least one processor is further configured to analyse and log real-time testing data gathered from the performed real-time testing of the at least one component of the vehicle using one or more data acquisition tools.
[0026] According to an aspect, the present embodiments, discloses a method for operating a hardware-in-the-loop (HIL) testing of a vehicle. The method comprising the steps of establishing, via one or more input/output (I/O) interfaces of a plurality of testing chambers, communication with at least one component of the vehicle under test through the plurality of testing chambers; providing, via at least one processor, one or more fixed input signals and one or more dynamic input signals to the at least one components through the one or more input/output (I/O) interfaces. Further, the at least one processor is communicatively coupled with a memory device and the plurality of testing chambers through the one or more input/output (I/O) interfaces. Further, the memory device is stored with one or more databases each having a vehicle simulation model, and the vehicle simulation model comprises one or more operating conditions of the vehicle and one or more environmental conditions. Further, the one or more fixed input signals and one or more dynamic input signals are generated by the vehicle simulation model; receiving, via the at least one processor, one or more output signals generated by the at least one component in response to the one or more fixed input signals and the one or more dynamic input signals; analysing, via the at least one processor, the one or more output signals, and generating, via the at least one processor, at least one report having the response of the at least one component.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] The accompanying drawings illustrate various embodiments of systems, methods, and embodiments of various other aspects of the disclosure. Any person with ordinary skills in the art will appreciate that the illustrated element boundaries (e.g., boxes, groups of boxes, or other shapes) in the figures represent one example of the boundaries. It may be that in some examples one element may be designed as multiple elements or that multiple elements may be designed as one element. In some examples, an element shown as an internal component of one element may be implemented as an external component in another, and vice versa. Furthermore, elements may not be drawn to scale. Non-limiting and non-exhaustive descriptions are described with reference to the following drawings. The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating principles.
[0028] FIG. 1 illustrates a block diagram of a hardware-in-loop (HIL) testing system for a vehicle, in accordance to an embodiment of the present invention;
[0029] FIG. 2A-2C illustrate perspective views of a plurality of testing chambers of the HIL testing system, in accordance to an embodiment of the present invention;
[0030] FIG. 3 illustrates a flowchart of the HIL testing system, in accordance to an embodiment of the present invention; and
[0031] FIG. 4 illustrates a flowchart showing a method for operating the HIL testing system for a vehicle, in accordance to an embodiment of the present invention.
DETAILED DESCRIPTION
[0032] Some embodiments of this disclosure, illustrating all its features, will now be discussed in detail. The words “comprising,” “having,” “containing,” and “including,” and other forms thereof, are intended to be equivalent in meaning and be open ended in that an item or items following any one of these words is not meant to be an exhaustive listing of such item or items, or meant to be limited to only the listed item or items. It must also be noted that as used herein and in the appended claims, the singular forms “a,” “an,” and “the” include plural references unless the context clearly dictates otherwise.
[0033] Although any systems and methods similar or equivalent to those described herein can be used in the practice or testing of embodiments of the present disclosure, the preferred, systems and methods are now described. Embodiments of the present disclosure will be described more fully hereinafter with reference to the accompanying drawings in which like numerals represent like elements throughout the several figures, and in which example embodiments are shown. Embodiments of the claims may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. The examples set forth herein are non-limiting examples and are merely examples among other possible examples.
[0034] FIG. 1 illustrates a block diagram of a hardware-in-loop (HIL) testing system (100) for a vehicle, in accordance to an embodiment of the present invention. FIG. 2A-2C illustrate perspective views of a plurality of testing chambers (102) of the HIL testing system (100), in accordance to an embodiment of the present invention.
[0035] In some embodiments, the HIL testing system (100) is used in development and validation of the vehicle by simulating and interacting with real-time hardware components. The vehicle comprises a car, truck, van, etc. The HIL testing system (100) is configured to verify that at least one component of the vehicle functions properly within the vehicle. The HIL testing system (100) is configured to combine the at least one component of the vehicle under test and a vehicle simulation model (110) to test and validate the at least one component of the vehicle under one or more predefined operating conditions. In some embodiments, the at least one component comprises at least a sensor, actuator, circuit boards, and power supply units.
[0036] In some embodiments, the HIL testing system (100) comprises a plurality of testing chambers (102) each comprising one or more input/output (I/O) interfaces (104), a memory device (108), and at least one processor (106). In some embodiments, the plurality of testing chambers (102) are configured to evaluate various operational, mechanical, and environmental parameters of the at least one component under test. In some embodiments, each testing chamber of the plurality of testing chambers (102) is configured to simulate different conditions. Further, the conditions comprise temperature extremes, humidity levels, pressure variations, vibration, and chemical exposure. Further, the plurality of testing chambers (102) are configured to ensure a comprehensive testing of performance, durability, and reliability of the at least one component of the vehicle.
[0037] Furthermore, the plurality of testing chambers (102) comprises an environmental chamber, a vibration chamber, corrosion chamber, electromagnetic compatibility (EMC) chamber, acoustic chamber, mechanical load testing chamber, and fluid immersion chamber. In some embodiments, the environmental chamber is configured to simulate extreme temperatures, humidity, and climatic conditions to assess thermal stability and material integrity of the at least one component. Further, the vibration chamber is configured to subject the at least one component to mechanical stress, replicating road conditions and structural fatigue scenarios.
[0038] In some embodiments, the corrosion chamber is configured to test resistance of the at least one component to salt spray, chemical exposure, and oxidation to evaluate longevity of the at least one component. Further, the EMC chamber is configured to measure resistance of the at least one component to electromagnetic interference (EMI). In some embodiments, the acoustic chamber is configured to analyse noise, vibration, and harshness (NVH) parameters to ensure compliance of the at least one component. In some embodiments, the mechanical load testing chamber is configured to determine structural strength and a load-bearing strength of the at least one component. In some embodiments, the fluid immersion chamber is configured to assess performance of the at least one component when exposed to fuels, lubricants, or other automotive fluid.
[0039] In some embodiments, each of the plurality of testing chambers (102) comprises the one or more I/O interfaces (104). Further, the one or more I/O interfaces (104) are configured to establish communication with the at least one component of the vehicle under test through the plurality of testing chambers (102). The one or more I/O interfaces (104) comprises analog interfaces, digital interfaces, and communication interfaces. The communication interfaces are selected from a group comprising Controller Area Network (CAN), Local Interconnect Network (LIN), and Ethernet. The one or more I/O interfaces (104) is configured to facilitate data exchange between the at least one processor (106) and the at least one component of the vehicle under test.
[0040] In some embodiments, the memory device (108) is communicatively coupled with the plurality of testing chambers (102). Further, the memory device (108) is configured to store one or more databases each having a vehicle simulation model (110). The vehicle simulation model (110) comprises one or more operating conditions of the vehicle and one or more environmental conditions. The vehicle simulation model (110) corresponds to at least one subsystem of the vehicle. The vehicle simulation model (110) serves as a digital twin of the at least one subsystem of the vehicle. The vehicle simulation model (110) replicates real-world conditions for the at least one component of the vehicle. The vehicle simulation model (110) corresponds to a mathematical representation of the vehicle. The vehicle simulation model (110) is created by the at least one processor (106) using matrix laboratory (MATLAB)/Simulink.
[0041] In some embodiments, the at least one subsystem of the vehicle comprises at least a powertrain, a battery management unit, a thermal management unit, and a control unit. The powertrain comprises at least a motor, an inverter, and a drivetrain. The battery management unit comprises at least state of charge (SoC), state of health (SoH), and thermal dynamics. The thermal management unit comprises at least a cooling system.
[0042] In some embodiments, the at least one processor (106) is communicatively coupled with the memory device (108) and the plurality of testing chambers (102) through the one or more input/output (I/O) interfaces (104). Further, the at least one processor (106) is configured to provide one or more fixed input signals and one or more dynamic input signals to the at least one components through the one or more input/output (I/O) interfaces (104). The one or more fixed input signals and one or more dynamic input signals are generated by the vehicle simulation model (110).
[0043] In some embodiments, the at least one processor (106) is configured to validate the vehicle simulation model (110). The at least one processor (106) is configured to simulate the vehicle simulation model (110) in Simulink to verify correctness of the vehicle simulation model (110). Validation involves simulating the vehicle simulation model (110) in the MATLAB/Simulink to verify accuracy, correctness, and real-time execution capability of the vehicle simulation model (110) before the vehicle simulation model (110) is deployed for testing at least one component of the vehicle.
[0044] Furthermore, the at least one processor (106) is configured to receive one or more output signals generated by the at least one component in response to the one or more fixed input signals and the one or more dynamic input signals.
[0045] In some embodiments, the at least one processor (106) is further configured to verify that the memory device (108) and processing capability are sufficient for handling computational load of the vehicle simulation model (110). The at least one processor (106) utilizes MATLAB’s profiling tools to estimate the computational load of the vehicle simulation model (110). The at least one processor (106) analyses memory consumption and processing power requirements.
[0046] In some embodiments, the at least one processor (106) is configured to perform real-time testing of the at least one component of the vehicle using the executed deployed vehicle simulation model (110). Further, the at least one processor (106) is configured to analyse the one or more output signals. Further, the at least one processor (106) is configured to generate at least one report having the response of the at least one component.
[0047] In some embodiments, the at least one processor (106) is configured to validate the at least one component of the vehicle under test by performing the real-time testing of the at least one component in isolation, injecting test signals to emulate the one or more predefined operating conditions, and processing drive cycle data to simulate real-time load demand. The at least one processor (106) is configured to inject test signals to replicate the one or more operating conditions. The one or more operating conditions further comprises at least one of acceleration profiles, and thermal variations.
[0048] In some embodiments, the HIL testing system (100) further comprises one or more testing equipment having at least one of signal conditioners, power supplies, and load simulators. The signal conditioners are configured to process one or more signals exchanged between the at least one processor (106) and the at least one component of the vehicle under test. The power supplies are configured to provide electrical power to the at least one component of the vehicle during real-time testing. The load simulators are configured to emulate electrical loads.
[0049] FIG. 3 illustrates a flowchart of the HIL testing system (100), in accordance to an embodiment of the present invention.
[0050] At operation 300, the at least one processor (106) is configured to define one or more testing objectives and criteria for conducting a closed-loop hardware-in-loop (HIL) test. The testing objectives and criteria correspond to the evaluation parameters of the at least one component of the vehicle. The testing objectives and criteria are stored in the memory device (108) and serve as a reference for configuring the HIL test setup.
[0051] At operation 302, the at least one processor (106) is configured to configure the HIL test setup. The HIL test setup comprises at least an electronic control unit (ECU), one or more simulation models, and a feedback mechanism. The ECU corresponds to the control unit of the at least one component of the vehicle. The simulation models replicate vehicle dynamics, environmental conditions, and road conditions. The feedback mechanism enables real-time response evaluation of the ECU under test.
[0052] At operation 304, the at least one processor (106) is configured to simulate the one or more environmental conditions through the plurality of testing chambers (102). The one or more environmental conditions comprise at least vehicle load, road conditions, and weather conditions. The simulated environmental conditions enable the assessment of the ECU’s performance under real-world operating scenarios.
[0053] At operation 306, the at least one processor (106) is configured to provide one or more fixed input signals to the ECU. The one or more fixed input signals comprise at least initial sensor data and vehicle speed. The one or more fixed input signals are generated by the vehicle simulation model (110) and transmitted to the ECU through the one or more input/output (I/O) interfaces (104).
[0054] At operation 308, the at least one processor (106) is configured to process the one or more fixed input signals using the ECU’s control logic and algorithms. The ECU processes the input signals based on pre-programmed control logic and generates one or more ECU output signals.
[0055] At operation 310, the at least one processor (106) is configured to generate one or more output signals. The one or more output signals comprise at least throttle position, braking commands, and steering commands. The generated one or more output signals are transmitted to the plurality of testing chambers (102) via the one or more I/O interfaces (104) for further evaluation.
[0056] At operation 312, the at least one processor (106) is configured to provide one or more dynamic input signals to the ECU based on the one or more output signals. The one or more dynamic input signals comprise vehicle speed, torque, and actuator responses. The one or more dynamic input signals enable real-time adaptation of the plurality of testing chambers (102) to simulate realistic driving conditions.
[0057] At operation 314, the at least one processor (106) is configured to simulate actuator and sensor responses of the at least one component. The actuator and sensor responses comprise at least actuator feedback, speed variations, and temperature changes. The simulated actuator and sensor responses are transmitted to the ECU for closed-loop evaluation.
[0058] At operation 316, the at least one processor (106) is configured to collect data and monitor the performance of the ECU. The collected data comprises system behavior, sensor feedback, and actuator responses. The at least one processor (106) is further configured to store the collected data in the memory device (108) for analysis.
[0059] At operation 318, the at least one processor (106) is configured to adjust one or more input signals based on the one or more output signals. The one or more adjusted input signals comprise at least speed variations and brake inputs. The adjusted input signals enable iterative testing of the ECU under varying conditions.
[0060] At operation 320, the at least one processor (106) is configured to analyze test results and evaluate the ECU’s performance. The analysis comprises comparison with predefined thresholds, failure detection, and control system response assessment. The at least one processor (106) is further configured to determine whether the ECU meets the required performance criteria.
[0061] At operation 322, the at least one processor (106) is configured to refine the plurality of testing chambers (102) and repeat testing as necessary. The refinement process comprises adjusting one or more test parameters, modifying feedback mechanisms, and updating test conditions. The at least one processor (106) ensures iterative improvement of the ECU evaluation process.
[0062] At operation 324, the at least one processor (106) is configured to end the HIL test and generate one or more test reports. The one or more test reports comprise at least the response of the at least one component, pass/fail results, and performance metrics. The generated reports are stored in the memory device (108) and can be retrieved for further analysis.
[0063] At operation 326, the HIL test process is terminated, and the evaluation results are recorded for future reference.
[0064] FIG. 4 illustrates a flowchart of a method (400) for the HIL testing of the vehicle, in accordance to an embodiment of the present invention.
[0065] At operation 402, the one or more I/O interfaces (104) are configured to establish communication with the at least one component of the vehicle under test through the plurality of testing chambers (102). The one or more I/O interfaces (104) comprises analog interfaces (104), digital interfaces (104), and communication interfaces (104). The communication interfaces (104) are selected from a group comprising Controller Area Network (CAN), Local Interconnect Network (LIN), and Ethernet. The one or more I/O interfaces (104) is configured to facilitate data exchange between the at least one processor (106) and the at least one component of the vehicle under test.
[0066] At operation 404, the at least one processor (106) is configured to provide one or more fixed input signals and one or more dynamic input signals to the at least one components through the one or more input/output (I/O) interfaces (104). The at least one processor (106) is communicatively coupled with the memory device (108) and the plurality of testing chambers (102) through the one or more input/output (I/O) interfaces (104). The memory device (108) is stored with one or more databases each having a vehicle simulation model (110), and the vehicle simulation model (110) comprises one or more operating conditions of the vehicle and one or more environmental conditions. The one or more fixed input signals and one or more dynamic input signals are generated by the vehicle simulation model (110).
[0067] At operation 406, the at least one processor (106) is configured to receive one or more output signals generated by the at least one component in response to the one or more fixed input signals and the one or more dynamic input signals. In some embodiments, the at least one processor (106) is configured to perform real-time testing of the at least one component of the vehicle using the executed deployed vehicle simulation model (110).
[0068] At operation 408, the at least one processor (106) is configured to analyse the one or more output signals. In some embodiments, the at least one processor (106) is configured to validate the at least one component of the vehicle under test by performing the real-time testing of the at least one component in isolation, injecting test signals to emulate the one or more predefined operating conditions, and processing drive cycle data to simulate real-time load demand.
[0069] At operation 410, the at least one processor (106) is configured to generate at least one report having the response of the at least one component. The one or more test reports comprise at least the response of the at least one component, pass/fail results, and performance metrics. The generated reports are stored in the memory device (108) and can be retrieved for further analysis
[0070] It should be noted that the hardware-in-loop (HIL) testing system (100) in any case could undergo numerous modifications and variants, all of which are covered by the same innovative concept; moreover, all of the details can be replaced by technically equivalent elements. In practice, the components used, as well as the numbers, shapes, and sizes of the components can be of any kind according to the technical requirements. The scope of protection of the invention is therefore defined by the attached claims.

Dated this 21st Day of February, 2025
Ishita Rustagi (IN-PA/4097)
Agent for Applicant
, Claims:CLAIMS
We Claim:
1. A hardware-in-loop (HIL) testing system (100) for a vehicle comprising:
a plurality of testing chambers (102) each comprising:
one or more input/output (I/O) interfaces (104) configured to establish communication with at least one component of the vehicle under test through the plurality of testing chambers (102);
a memory device (108) stored with one or more databases each having a vehicle simulation model (110), wherein the vehicle simulation model (110) comprises one or more operating conditions of the vehicle and one or more environmental conditions;
at least one processor (106) communicatively coupled with the memory device (108) and the plurality of testing chambers (102) through the one or more input/output (I/O) interfaces (104), wherein the at least one processor (106) is configured to:
provide one or more fixed input signals and one or more dynamic input signals to the at least one components through the one or more input/output (I/O) interfaces (104),
wherein the one or more fixed input signals and one or more dynamic input signals are generated by the vehicle simulation model (110),
receive one or more output signals generated by the at least one component in response to the one or more fixed input signals and the one or more dynamic input signals,
analyse the one or more output signals, and
generate at least one report having the response of the at least one component.

2. The HIL testing system (100) as claimed in claim 1, wherein the plurality of testing chambers (102) further comprises at least a powertrain, a battery management unit, a thermal management unit, and a control unit.

3. The HIL testing system (100) as claimed in claim 1, further comprising one or more testing equipment communicatively coupled to the one or more I/O interfaces (104), wherein the one or more testing equipment comprises at least one of signal conditioners, power supplies, and load simulators.

4. The HIL testing system (100) as claimed in claim 3, wherein the signal conditioners are configured to process the one or more fixed input signals and one or more dynamic input signals, and wherein the power supplies are configured to provide electrical power to the at least one component of the vehicle during real-time testing, and wherein the load simulators are configured to emulate electrical loads.

5. The HIL testing system (100) as claimed in claim 1, wherein the one or more I/O interfaces (104) comprises analog interfaces (104), digital interfaces (104), and communication interfaces (104).

6. The HIL testing system (100) as claimed in claim 1, wherein the one or more operating conditions, comprises real-world driving conditions, fault injection scenarios, and environmental variations, wherein the one or more predefined environmental conditions comprises temperature, humidity, vibrations, and moisture.

7. The HIL testing system (100) as claimed in claim 1, wherein the at least one processor (106) is further configured to validate the at least one component of the vehicle under test by performing the real-time testing of the at least one component in isolation, injecting test signals to emulate the one or more predefined operating conditions, and processing drive cycle data to simulate real-time load demand.

8. The HIL testing system (100) as claimed in claim 1, wherein the at least one processor (106) is further configured to verify real-time the execution of the deployed vehicle simulation model (110) without delays or jitter.

9. The HIL testing system (100) as claimed in claim 1, wherein the at least one processor (106) is further configured to analyse and log real-time testing data gathered from the performed real-time testing of the at least one component of the vehicle using one or more data acquisition tools.

10. A method (400) for operating a hardware-in-the-loop (HIL) testing system (100) for a vehicle, comprising:
establishing, via one or more input/output (I/O) interfaces (104) of a plurality of testing chambers (102), communication with at least one component of the vehicle under test through the plurality of testing chambers (102), at operation (402);
providing, via at least one processor (106), one or more fixed input signals and one or more dynamic input signals to the at least one component through the one or more input/output (I/O) interfaces (104),
wherein the at least one processor (106) is communicatively coupled with a memory device (108) and the plurality of testing chambers (102) through the one or more input/output (I/O) interfaces (104),
wherein the memory device (108) is stored with one or more databases each having a vehicle simulation model (110), and the vehicle simulation model (110) comprises one or more operating conditions of the vehicle and one or more environmental conditions,
wherein the one or more fixed input signals and one or more dynamic input signals are generated by the vehicle simulation model (110) , at operation (404);
receiving, via the at least one processor (106), one or more output signals generated by the at least one component in response to the one or more fixed input signals and the one or more dynamic input signals, at operation (406);
analysing, via the at least one processor (106), the one or more output signals, at operation (408); and
generating, via the at least one processor (106), at least one report having the response of the at least one component, at operation (410).
Dated this 21st Day of February, 2025
Ishita Rustagi (IN-PA/4097)
Agent for Applicant