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Taking ABS/ESP as an example, the paper will show different configurations of Hardware-in-the-Loop (HIL) test systems, namely the ABS/ESP ECU HIL and the brake system HIL. The HIL simulation will be demonstrated with the vehicle dynamics simulation environment CarMaker. CarMaker maps realistically all subcomponents of the vehicle like suspension, steering, braking, tires, masses and aerodynamics. Using it, longitudinal, lateral and vertical dynamic scenarios can be simulated with sophisticated driver, traffic and 3D road models in a full test automation process. Functions, failures, failsafe methods, security functions and the performance of the control systems can be analyzed and evaluated comprehensively. This will be illustrated with concrete simulation examples with different vehicle/engine options, equipment levels, tire conditions and changing environmental conditions (road conditions, cross wind).

The evaluation of vehicle characteristics at an early phase of functional development is a key task in the definition of a viable system architecture. Today this is complicated by the fact that full vehicle characteristics, in particular those of modern hybrid vehicles, are dependent on a broad range of electrical, mechanical, thermal and control-related partial aspects. In addition to the current driving status and information on the environment, modern energy management systems (e.g. control systems, range, charging and thermal management) also require predictive information on the driving route to be expected. This includes, for example, uphill road grades, curve radii, speed limits, number of lanes, urban and residential areas, intersections and traffic lights. All together, the intelligent fusion of this information provides for increased safety and energy efficiency.