The boundary between the virtual and physical world is constantly evolving and becoming ever more blurred. Nowhere is this truer than in the realm of the development and testing of vehicles, both in mainstream automotive and motorsport. The virtualisation of testing through simulation and modelling allows for much expensive physical prototyping to be avoided, and is now a necessity in many current racing series, thanks to extensive restrictions on track testing.
However, there is only so much that can be achieved in the purely virtual domain, and the sooner physical components can be introduced into the picture the better. This is where X, or everything-in-the-loop testing, comes into play. Put simply, it’s the integration of physical and software components into models and, not to be forgotten, the driver.
Various in-the-loop testing methods have been commonplace in racing for years, but the arrival of electrified powertrains has increased their importance considerably. Racecars are now heavily software dependent. Thirty years ago, there was only really an engine and its associated ECU to worry about. Now some cars incorporate multiple motors, inverters and battery systems in addition to the ICE, as well as elements such as brake-by-wire systems. Ensuring these are singing together in perfect harmony requires a system level approach to simulation and testing.
To complicate matters further, the various hardware and software elements invariably become available at different stages in the development process, and this is where hardware and software-in-the-loop testing can be invaluable in proving out these complex systems
