Evaluation and tuning of brake systems – from simulation to the test bench
MXbrakeHiL: A Hardware-in-the-Loop Test Environment for Brake System Development and ESC Validation
MXbrakeHiL is a Hardware-in-the-Loop (HiL) test system that integrates a complete physical brake assembly—from the brake pedal through to the brake calipers—directly into a real-time vehicle simulation environment. This enables the testing, evaluation, and tuning of ESC ECUs and safety-critical braking functions before a vehicle prototype is available. And it reduces simulation complexity and supports systematic validation at each stage of the V-model.
Electric and automated vehicles require precise development of braking functions and vehicle dynamics controllers. Pure simulation models have limitations in replicating the hydraulic nonlinearities, friction, and valve dynamics present in physical brake systems. MXbrakeHiL addresses this by substituting real hardware into the control loop, removing the need to model those physical effects mathematically.
MXbrakeHiL – structure
The proven, cross-component test bench architecture
Hardware-Coupled Testing: Physical Response, Repeatable Conditions, Objective Evaluation
Physical Fidelity Through Unmodified Hardware Components: Unmodified hardware components reproduce authentic pressure build-up rates, dynamic hysteresis, and ABS modulation profiles — behavior that parametric simulation models cannot reliably replicate.
Repeatable Scenario Testing: Road surface conditions, vehicle speeds, and environmental factors are defined in the simulation model and varied systematically to validate functions including Autonomous Emergency Braking (AEB) and ESC, with consistent initial conditions across every run.
Open Architecture for Parameter Optimization: The test bench supports complex parameter sweeps and calibration variant evaluations. Full observability of the hardware chain and integration with MXeval allow engineers to evaluate criteria such as stability, brake blending logic, and hardware interaction in a single test cycle.
Objective KPI-Based Evaluation and Early Validation Across the V-Model
MXbrakeHiL is structured for model-based systems engineering workflows.
- Automated KPI Evaluation via MXeval Integration: The test bench is fully integrated with MXeval, providing automated, KPI-based analysis of brake system performance. This enables structured, data-driven evaluation of metrics including pedal force progression, stability, and pressure build-up dynamics.
- Front-Loading Validation Across the V-Model: By front-loading testing and validation across all V-model stages, engineers can optimize design parameters and resolve functional errors early, reducing the volume of track testing required later in the programme – it overall accelerates development.
Real-Time System Compatibility and Modular Configuration
MXbrakeHiL interfaces with the major real-time simulation platforms used in automotive brake and vehicle dynamics development: RT Systems such as VI-grade AutoHawk, Concurrent Real-Time iHawk, Vector VN & VT, dSpace Scalexio, IPG Xpack and more.
Supported vehicle models are Vector DYNA4, IPG CarMaker, dSpace ASM, and custom MATLAB/Simulink. The system is designed for seamless interfacing with these platforms without additional adaptation layers.
The hardware configuration is modular. The test bench can be configured with additional sensors, actuators, or universal emulation modules to match specific test requirements, allowing the system to be adapted to different project needs without fundamental architectural changes.
Key Facts of MXbrakeHiL
- Brake system compatibility: Full wet physical brake assembly integrated into the loop — from brake pedal to brake calipers
- Test coverage: Supports HiL-DiL test configurations — from early ESC software integration through system-level validation in the V-model
- High precision: Authentic reproduction of pressure build-up dynamics, dynamic hysteresis, and ABS modulation profiles through real hardware components
- Modular, scalable design: Open, modular design with quick-swap setups; configurable with additional sensors, actuators, or universal emulation modules
- Real-time integration: Compatible with all EtherCAT-supporting real-time systems including VI-grade AutoHawk, Concurrent Real-Time iHawk, Vector VN & VT, dSpace Scalexio, IPG Xpack and more
- Software compatibility: Full integration with MXeval for automated, KPI-based evaluation of brake system performance
- Plug & Play: Straightforward commissioning through pre-configured interfaces
- Vehicle models: Supports commercial vehicle models including Vector DYNA4, IPG CarMaker, dSpace ASM, and custom MATLAB/Simulink vehicle models
- Measurement: Full observability of the hardware chain throughout each test run
- Optimisation: Supports complex parameter sweeps and calibration variant evaluations
- V-model coverage: Supports testing and validation across all maturity levels of the V-mode
Benefits of MXbrakeHiL for Development and Validation Teams
- Removes hydraulic modelling dependency: unmodified physical hardware in the loop eliminates the need to build and validate hydraulic simulation models for each hardware variant
- Reduces prototype dependency: ESC ECU software can be tested and validated against real brake hardware before a vehicle prototype is available
- Repeatable, controlled test conditions: road surface, speed, and environmental parameters are defined in simulation, removing variability from test execution
- Automated regression testing: parameter or software changes can be evaluated against the same test scenarios without continuous manual bench operation
- Objective, structured KPI outputs: MXeval integration produces consistent evaluation results covering pedal force progression, stability, and pressure build-up dynamics but also complex KPIs for slalom or lane change maneuvers
- Compatibility with existing toolchains: direct interfacing with RT Systems and vehicle models from VI-Grade, Vector, IPG, dSpace, and MATLAB/Simulink
- Configurable hardware platform: modular architecture supports additional sensors, actuators, or emulation modules to match project-specific requirements
- Earlier error detection: functional issues in brake control logic or ESC calibration are identified at the bench, earlier in the V-model where correction is less costly
- Full hardware chain observability: all signals throughout the brake hardware assembly are accessible for analysis during each test run
MXbrakeHiL Impressions
MXbrakeHiL is designed for development and validation teams working on ESC software, brake system calibration, and safety-critical braking functions. Contact us to discuss your test system requirements.