As electric vehicle architectures evolve toward higher levels of electrification, managing power flow across multiple voltage domains is becoming increasingly complex. To address these challenges, dSPACE is providing an integrated portfolio of simulation, prototyping, and validation technologies that enable manufacturers to develop and optimize next-generation power management systems for battery electric vehicles (BEVs), plug-in hybrid electric vehicles (PHEVs), hybrid electric vehicles (HEVs), and fuel cell electric vehicles (FCEVs).
Modern electric vehicles rely on sophisticated power electronics to transfer energy efficiently between high-voltage batteries, onboard chargers, traction systems, low-voltage networks, and auxiliary loads. The growing adoption of wide-bandgap semiconductors, higher switching frequencies, and multi-voltage electrical architectures is driving the need for more advanced development and testing methodologies. dSPACE's technology portfolio is designed to support these requirements throughout the entire product development cycle.
The company offers solutions for developing and validating power conversion systems, ranging from standalone DC/DC converters to highly integrated power management units that coordinate multiple energy sources and loads. The technologies support AC/DC converters used in onboard charging systems, high-efficiency DC/DC converters that provide 12 V and 48 V auxiliary power, and bidirectional converter architectures used in mild-hybrid and fuel-cell vehicle platforms.
To enable rapid controller development, dSPACE provides scalable rapid prototyping systems that allow engineers to implement and evaluate new control algorithms before production hardware becomes available. The approach helps accelerate mechatronic control design and facilitates early-stage optimization of converter performance and energy management strategies.
A major pillar of the company's technology portfolio is its Hardware-in-the-Loop (HIL) testing capability. The HIL systems create highly realistic virtual environments in which electronic control units and power electronics controllers can be validated under reproducible laboratory conditions. These systems support continuous 24/7 testing and cover applications ranging from component-level validation to full virtual vehicle development.
The company's HIL solutions incorporate nanosecond-level gate signal processing and FPGA-based real-time simulation technologies capable of reproducing the behavior of complex power electronic topologies. Ready-to-use FPGA libraries and topology-based models enable accurate simulation of converters and switching circuits while supporting distributed multi-FPGA configurations through high-speed optical communication interfaces.
As switching frequencies continue to increase with the adoption of silicon carbide (SiC) and gallium nitride (GaN) devices, conventional simulation approaches face increasing challenges. dSPACE addresses these requirements through its Electrical Power Systems Simulation (EPSS) package and XSG Power Electronics Systems libraries. These technologies enable high-speed real-time simulation of fast-switching resonant converters and complex power electronic circuits while eliminating the need for extensive FPGA programming expertise.
The company also offers Power Hardware-in-the-Loop (Power HIL) systems that bridge the gap between signal-level simulation and full dynamometer testing. By operating with real voltages and currents, these platforms provide a digital twin environment capable of evaluating complete inverter systems, onboard chargers, and power converters under realistic operating conditions. The systems are designed to simplify test configuration while significantly reducing setup times and enabling rigorous validation at full power levels.
Beyond hardware-based validation, dSPACE supports Software-in-the-Loop (SIL) testing, allowing developers to evaluate embedded software and control algorithms in PC- and cloud-based environments. The modular framework enables scalable virtual testing and facilitates seamless reuse of test scripts across SIL and HIL platforms, improving development efficiency and traceability.
Simulation modeling forms another important element of the company's technology strategy. Mathematical real-time models and digital twins enable engineers to predict system behavior and evaluate performance under a wide range of operating scenarios. These capabilities are increasingly important as automakers seek to optimize converter efficiency, reduce system weight and volume, and improve overall vehicle energy management.
The technologies are applicable across a broad range of e-mobility systems, including onboard chargers, bidirectional DC/DC converters, battery management systems, fuel-cell powertrains, charging infrastructure, and traction drive systems. Through integrated tool chains spanning software development, simulation, prototyping, and validation, dSPACE aims to help manufacturers accelerate the development of increasingly efficient and reliable electrified vehicles.
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About dSPACE
dSPACE is a Germany-based provider of simulation, validation, and development solutions for automotive and industrial applications. The company specializes in Hardware-in-the-Loop testing, Software-in-the-Loop testing, rapid prototyping, real-time simulation, and digital twin technologies. Its solutions are widely used in the development of electric vehicles, battery management systems, charging infrastructure, autonomous driving systems, and power electronics, enabling manufacturers worldwide to accelerate innovation while improving product quality and reliability.
