Submitted 03/2026
HIL Platform for BMS SCALEXIO
SCALEXIO Battery HIL
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Product Context
dSPACE's SCALEXIO Battery HIL (Hardware-in-the-Loop) is a real-time validation environment used for testing and validating (Battery Management System) BMS functionality during the Battery Module Development process. It's a modular and scalable system designed for development and validation of BMS at signal, high-voltage and virtual levels.
Inputs
Optional
Outputs
Technial Parameters
- Developing & refining & validating BMS functionalities during development
- Signal Level HIL Testing: Validating the physical BMS controller by simulating the Cell Supervision Circuits (CSC) and their communication via communication protocols like CAN, SPI, or isoSPI. This is ideal for early integration and testing the "logic" of the controller both compactly and cost efficiently without high-voltage risks.
- High-Voltage Validation & Safety Certification: Testing the entire BMS system, including physical , under real electrical loads up to 1500 V. This stage is used for final release, acceptance testing, and achieving ISO 26262 Functional Safety compliance.
- BMS HW
- CSC HW (or emulated)
- BMS algorithm System parameters
- Battery models (ASM)
Model-based real-time emulation of cell voltages, temperatures, balancing currents, Shunt sensor voltages and high-voltage sensor signals for BMS response validation
- Compatible with all current and future chemistries through parametrizable ASM battery models
- System voltages up to 1500V. No cell limit.
- Cell voltage emulation with up to 300µV and balancing currents up to 20A
- CAN, SPU, I2C, isoSPI (Analog Devices), VIF (Texas Instruments), and TLP(NXP)
- Supports various cell controllers from major vendors like NXP, TI, Analog Devices.
- Real-time capable, multi-cell Simulink-based models from dSPACE ASM (Automotive Simulation models) battery model library.
- Including cell chemistry, aging, thermal dynamics, and failure models.
- Soft BMS ECU for easy model setup even without physical BMS ECU
- Battery chemistry & cell configurations can be changed using the ModelDesk tool which then updates underlying Simulink parameters.
Product Sheets
Product Information in Detail
- The SCALEXIO Battery HIL (Hardware-in-the-Loop) Platform is a high-performance, real-time validation environment specifically engineered for the rigorous testing of Battery Management Systems (BMS). It serves as the critical physical bridge between virtual software simulation and vehicle production, ensuring that BMS hardware can reliably manage the electrical stresses and communication complexities of modern electrified powertrains.
- At the core of the solution is the ability to provide high-precision cell voltage emulation with up to 300 µV accuracy. This allows engineers to "trick" a physical BMS controller into perceiving a live battery environment. The system supports a wide range of configurations:
- High Voltage Capability: Supports system voltages up to 1500 V.
- Current Handling: Supports currents up to 20 A for active/passive balancing tests.
- 4 channel cell boards DS5482 for compact and cost efficient test systems
- 8 channel temperature sensor simulation board DS5486
- 2 channel high voltage source board DS5488
- By using Failure Insertion Units (FIU), engineers can safely simulate dangerous failure modes—such as internal cell shorts, sensor wire breaks, or insulation faults—in a 100% reproducible laboratory setting without the fire risks associated with real high-voltage batteries.
- The system integrates seamlessly with dSPACE ASM Battery (Automotive Simulation Models). These Simulink-based models are completely open and parameterizable via the ModelDesk tool, allowing for the simulation of: Diverse cell chemistries (LFP, NMC, etc.). Complex thermal dynamics and aging effects. SOC (State of Charge) and SOH (State of Health) algorithm benchmarking.
- The SCALEXIO hardware is housed in a robust 19" industrial rack system, available in various sizes from compact 18HE units to 41HE Superset variants. The modular architecture includes:
- Real-Time Processor (RTPC): For high-speed computation of battery models.
- Various I/O Boards for cell voltage emulation, temperature sensor emulation and output of Pack battery voltages up to 1.500V.
- Multi-Protocol Support for signal based BMS testing using Cell Controller Virtualization: Full compatibility with CAN, SPI, isoSPI (Analog Devices), VIF (TI), and TLP (NXP), ensuring support for all major cell controller vendors.
- Testing is streamlined through AutomationDesk, which utilizes block-based test case libraries for fully automated execution. This enables continuous integration (CI) workflows where BMS software builds are automatically validated against thousands of test scenarios overnight, ensuring rapid development cycles and high-quality software releases.
Features & USPs
Reduce Time-to-Market
Early validation through "frontloading" before real battery hardware is available.
Cost Saving
Eliminates the need for expensive and hazardous real battery packs during the bulk of software validation.
SIL to HIL
Seamless transition from SIL to HIL: Direct reuse of test cases from SIL (Software-in-the-Loop) to HIL
High Accuracy Test Equipment
Cell emulation with up to 300 µV precision for accurate SOC/SOH estimations and safety routines. Up to 20 A current for high power validation for active balancing or fast charging.
Scalability
Modular design supporting from configurations up to 1500V per system.
More Technical Details
- 19" industrial rack system.
- Available in Compact (18HE/23HE/32HE) and Superset (41HE) variants
- Steel industrial cabinets with internal cooling paths and rear cabling access.
- Includes real-time processor (RTPC)
- Cell emulation boards (DS5481, DS5482)
- Failure insertion units (FIU)
- Temperature emulation modules (DS5486)
- High-voltage source board (DS5488)
Closed-loop assessment of SoC (State of Charge), SoH (State of Health), and isolation resistance monitoring
Fully automated test execution via AutomationDesk with block-based test case libraries
Service & Support Offerings
Global network for installation, maintenance, and expert process design.
dSPACE engineering services and process consulting to optimize HIL integration into existing toolchains
- Standard Training: A dedicated course for SCALEXIO platforms
- AutomationDesk: Focused on automated regression testing, custom library development, and failure insertion (FIU) management
- ControlDesk Advanced: Covers complex instrumentation, the Bus Navigator, and advanced signal editors for high-fidelity diagnostics
- BMS-Specific Training: Targeted tutorials on transitioning from SIL to HIL validation, interpreting BMS error messages, and validating safety-critical firmware close to production code
- Real-time data visualization: ControlDesk serves as the primary remote interface, allowing engineers to visualize model variables on instrument panels and record data sets in real-time.
- Synchronized monitoring: SCALEXIO supports synchronized bus monitoring for CAN, LIN, and Ethernet protocols without requiring additional hardware.
- Fault interpretation: The platform enables remote interpretation of test results and error messages for safety-critical systems, such as detecting undervoltage faults in real-time.
- Diagnostic integration: Supports Unified Diagnostic Services (UDS) communication and works alongside third-party tools like CANalyzer for deep-dive remote network analysis on simulated CAN buses.
- Troubleshooting support: dSPACE engineering services and the SYNECT portal provide technical documentation and calibration support to ensure simulators match evolving project requirements.
Future-proofed modular design for easy addition of future cell emulation, temperature sensor emulation, or communication modules