HIL
TEST
SYSTEM
FOR
VCU

Background

Our client is a leader in sustainable energy solutions and required a stable Hardware-in-the-Loop (HIL) testing system to support developing and validating a new Vehicle Control Unit (VCU). As the VCU plays a critical role in managing vehicle subsystems, it needed a test platform to simulate varying operational and fault scenarios before real-world deployment.

The challenge was to deliver a scalable, flexible, and powerful HIL environment allowing engineers to assess system performance, resilience, and reliability under controlled lab conditions. Elevate Controls was engaged to design, develop, and deploy four turnkey HIL systems to meet this need.

The Challenge

Designing a high-performance HIL testing system for such a complex controller required solutions to several technical challenges. The system needed to:

  • Support over 700 analog and digital I/O channels for detailed simulation coverage.
  • Integrate various communication protocols, including Flexible Data Rate CAN, CANOpen, RS-232/485, and Ethernet-based ModBUS TCP.
  • Provide fault-insertion capability across both base I/O and Load Box channels to simulate real-world failure modes.
  • Include a custom high-power Load Box to replicate the electrical demands faced in operational environments.
  • Feature a modular, scalable hardware design with user-friendly software to facilitate ongoing customisation.
  • Be delivered as a complete dual 19” rack solution with sub-rack modularity, custom interconnects, and an intuitive graphical user interface (GUI).
Fibre optics connected in a system

The Solution

Elevate Controls delivered a fully integrated HIL test platform tailored to VCU validation. Built on industry-leading NI (National Instruments) PXI hardware and driven by NI LabVIEW, TestStand, and VeriStand software, the system offered flexibility, accuracy, and scalability.

Key features and capabilities

Extensive I/O coverage:

  • With over 700 analog and digital input/output channels, the HIL system allowed for thorough and repeatable test sequences across a wide operational range.

Multi-protocol communications:

  • The tester supported a full suite of interfaces, including CAN FD, CANOpen, ModBUS TCP, and serial RS-232/485 protocols, ensuring integration with the VCU’s real-world communication requirements.

Advanced fault insertion:

  • Engineers could induce and evaluate failure modes via built-in fault injection mechanisms on most base I/O lines and all Load Box channels—essential for stress-testing safety-critical systems.

Custom load simulation:

  • A bespoke high-power Load Box and signal conditioning modules accurately simulated the electrical profiles encountered in actual vehicle environments, enabling realistic and reliable testing.

Scalable, modular architecture:

  • Designed for future expansion, the system’s modular sub-racks and configurable software framework allow easy updates to I/O capacity and protocol support as development progresses.

User-driven automation:

  • Engineers benefited from an intuitive GUI and automation suite built in LabVIEW and TestStand. Without extensive programming knowledge, users could design and execute detailed test routines, increasing development speed and reducing errors.

Turnkey rack-mount deployment:

  • Each system was supplied as a dual 19” rack with custom signal routing, integrated power management, screen-printed panels, and ready-to-run capability, ensuring a simple setup and minimal downtime.

The Outcome

Our client operates four HIL testing systems for its VCU validation process. These platforms enable the engineering team to run comprehensive simulations, inject fault conditions, and ensure each VCU is functionally sound before vehicle integration.

The HIL systems have improved the development cycle’s speed, accuracy, and confidence. Users can test edge cases, validate communications, and simulate high-load environments from within a controlled lab setting.

Elevate Control is committed to delivering intelligent, future-ready test platforms. With deep experience in integrating COTS hardware, custom electronics, and automated test systems, we empower engineering teams to test smarter, iterate faster, and launch with confidence.

Our Approach

Every control, monitoring, or test system project is unique. Elevate Controls follows a consistent development process that adapts to the unique requirements of your project and delivers a quality outcome every time. We use industry-standard tool chains that ensure consistent and efficient application of resources across every stage.

We offer a full-cycle development service from concept to deployment, and every stage in between. Whether you’re starting from a blank page or optimising an existing system, our team brings deep industrial experience, technical know-how, and a problem-solving mindset to every project.

Concept Validation

System Architecture

System Development

Deployment & Scaling

Maintenance & Evolution
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Our Services

Embedded Controllers

Elevate Controls offers full-cycle development of embedded controllers. Our consistent development process adapts to the unique requirements of your project and ensures a quality outcome every time. We use industry standard tool chains that ensure efficient use of resources, and design protect to allow for future variation and scalability.

Measurement & Automation

We supply custom measurement and automation systems for application in technology-based industries including mining & materials handling, renewable energy & power, transport, and manufacturing.

Our systems deliver superior performance for demanding applications that push the limits of traditional data loggers and PC/PLC controllers.

MatLab/Simulink Services

We are expert integrators of the Mathworks MATLAB/Simulink software toolchain for system modelling, simulation and control design of complex engineering applications.

Vehicle/Engine Control Units

We design, develop, validate and certify high-volume Vehicle/Engine Control Units.

We are a proven partner for VCU/ECU development with over 100,000 units currently in service.

Product Development and Supply

Elevate Controls can partner with you to develop your control, measurement, or automation product. We can manage the entire process to the point of handover or work as an embedded part of your product development team.

We develop products using fully documented industry-standard processes and toolsets that ensure that your product can be maintained, evolved, and supported for it’s projected commercial life.

We employ a consistent development methodology that delivers successful outcomes every time.

Test Systems

Elevate Controls develops custom test systems that are integral to every successful industrial or manufacturing business. Test guides and validates product development, tracks and maintains product quality, and is an essential element of post-production support and warranty management.

Specialised Industrial Automation

Elevate Controls specialises in custom solutions to industrial automation challenges that push the limits of traditional PLC/SCADA systems. We target challenging industrial R&D or test applications, specialised sub-systems within a traditional DCS, and process control for niche or pilot-scale manufacturing.

We have supplied systems to industries that include mining and materials handling, electrical power, transport, manufacturing, process industries, agribusiness, and engineering services.

We do not compete directly in the large-scale DCS or SCADA space.

Engineering Data Management

Traditional data management lags behind the exponential growth in the volume and variety of data collected in modern engineering workplaces.

Elevate Controls’ Engineering Data Management Solution is designed to meet the needs of small to medium-sized engineering groups that must manage, analyse, and report large quantities of mixed-signal data.

NI Alliance Partner

Elevate Controls is an NI Systems Integration Partner with over 30 years’ experience deploying NI-based systems into Australian industry.

We are one of Australia’s most awarded integrators of NI systems at leading industry events.

We have hands-on experience with all NI’s current & legacy hardware lines, and all NI software applications & frameworks. We are one of Australia’s leading LabVIEW software development houses, having worked with every version of LabVIEW since its initial release.

Fibre Optic Measurement

Fibre Optic Measurement delivers some unique benefits that complement the functionality of traditional electro-mechanical sensing systems.

Elevate Controls can deliver measurement and automation systems that seamlessly integrate Fibre Optic Measurement into traditional electro-mechanical sensing systems. This can address issues that may be challenging or impossible to meet with electro-mechanical sensors alone.

Contact Us

Our solutions leverage industry-leading platforms, including National Instruments hardware and software, ensuring reliability, scalability, and faultless integration with your existing infrastructure.

We partner with clients throughout the entire project lifecycle—from proof of concept to system development, deployment, and long-term support— with the added flexibility to integrate at any phase of your project.

Elevate Controls helps businesses accelerate innovation while optimising performance and cost.

Contact us today to discuss your specific requirements and discover how Elevate Controls drives efficiency, accuracy, and competitive advantage in your operations.



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