P-HIL Applications without any If’s or But’s

Don’t look to the stars – solid simulation technology is within your reach! Innovative P-HIL testing solutions: Meet REGATRON at the upcoming trade shows!

RegaLink RT: Discover REGATRON’s Latest Advancements in Power Hardware-in-the-Loop!

Power Hardware-in-the-Loop (P-HIL) is an advanced simulation technique that has become essential for developing and testing modern electrical systems. In a P-HIL environment, real hardware is seamlessly integrated into a real-time simulation, enabling accurate and reliable evaluation of system time response under real-world conditions.

P-HIL applications are highly dependent on the following two characteristics of the system:
a) High resolution of the relevant data
b) Highest possible system dynamics

The system dynamics are composed of both the reaction time of the power stage and the communication delay time between the HIL system and the amplifier. Therefore, the functionality of REGATRON’s G5 DC amplifiers has been expanded with a new high-speed data interface for P-HIL applications.

The basis of the NEW RegaLink RT interface is the Aurora protocol. This protocol is a lightweight, high-speed, point-to-point serial communication protocol for transferring data between FPGAs using multi-gigabit transceivers. REGATRON G5 units are using the SFP (small form-factor pluggable) standards with optical cables between the amplifier and the HIL system. Not only the dynamic data transfer values have been remarkably improved, but the previous analogue data transmission has also been converted to a digital data format. In addition to a significant gain in stability and accuracy, instantaneous values for voltage and current can now be transmitted simultaneously.

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Maximum Speed or Minimum Overshoot?

The following screenshots show both shortest communication delay times (<60 µs) from the HIL model to power out and the quick response time of the power stage (<50 µs in CC mode). Figure 1 shows that the dynamic behaviour of the G5 devices can be easily adapted to a specific task. Various features such as switchable filter time constants and adjustable controller settings as well as the integrated powerful 8-channel digital scope assist the user to quickly and easily achieve optimal system behaviour for a special application requirement either for constant voltage or for constant current operation.

The two screenshots show a parameterization example of a 36 kW, 500 V, 216 A device: Set-value step current -150…150 A@180 VDC in <50 μs with overshoot (left), in <200 μs w/o overshoot (right). This dynamic behaviour is characteristic for all G5 devices as also for any multi-unit array!

Green: Start of data transfer from HIL to amplifier
Red: Response of the load current
Yellow: Voltage of the DUT
Time basis: 50 µs / div

Relevant DC Applications for P-HIL

REGATRON G5 DC power supplies in P-HIL testing are applied in various areas within electrical and energy engineering:

Battery simulation: Investigation by means of simple to sophisticated electrical equivalent circuits
Smart grid test setup: Real-time simulation of complex network scenarios with energy sources such as photovoltaics or fuel cells, or energy storage/conversion systems such as batteries or electrolysers
DC distribution grids: Simulation of dynamic DC loads for stability testing of complex networks on large ships, aircrafts, and complex stationary installations and systems
Inverter testing: Stability and power testing by variations of input and output variables under real-time conditions

Meet us at Trade Shows!

REGATRON’s DC and AC power supplies meet the very demanding requirements of P-HIL power amplifiers thanks to their high dynamics and precision. In addition to specific P-HIL applications, REGATRON offers a whole range of products that meet almost all requirements of industry, universities, development and research laboratories in terms of power, voltage, or current. The specific product ranges include programmable AC and DC power supplies, battery simulators, chargers, four-quadrant grid simulators, electronic loads, battery testers, and drive cycle test devices.

At the upcoming ECCE conferences in Birmingham UK and Philadelphia USA, REGATRON will be demonstrating the all-in-one DC power supply G5.UNV with industry leading dynamics with switchable capacitance. A current step between 90% sourcing to 90% sinking terminates as quick as 50 µs. In addition to the programmed output power, a current ripple with frequencies up to 10 kHz can be modulated, which is important for modern Electrochemical Impedance Spectroscopy EIS. Modules are available from 9 kW to 54 kW at 60 V to 1500 V, with outputs up to the MW range and voltages up to 3000 V in master/slave.

The versatile AC power source/sink TC.ACS will also be on display. All three of the unit’s output phases are individually programmable for voltage, frequency, phase angles and superimposed harmonics. Current control is also available. GUIs allow a variety of grid conditions and RLC topologies to be emulated. A special Fourier tool can create virtually any conceivable periodic waveform, with superimposed harmonics and inter-harmonic voltages up to 5000 Hz.

Talk to us about the above-described fibre optic interface using the Aurora protocol for both AC and DC systems. In close collaboration with key HIL suppliers, the interface is due to be released for the DC units end of 2025 and for AC units early 2026. The interface can also be retrofitted into devices that have already been installed.

ECCE Europe | Birmingham | September 1–3, 2025
Visit the joint booth 11 of Regatron AG and ETPS Ltd
ECCE USA | Philadelphia | October 20–21, 2025
Visit the booth 221 of Regatron Inc.