New Breakthrough in Full Topology HIL Simulation Testing for On-Board Chargers
SHINRY
Automotive
06 / 04 / 2026
The company
SHINRY Technologies Co., LTD. (referred to as SHINRY, stock code: 300745.SZ), founded in 2005 and headquartered in Shenzhen, is a National High-Tech Enterprise specializing in EV, FCEV, and High-end Equipment. As a pioneer in the on-board power segment, SHINRY holds full independent intellectual property rights for its core technologies, including on-board DC/DC converters, On-Board Chargers (OBC), and integrated products, serving global automotive leaders.
Starting in June 2025, SHINRY partnered with OPAL-RT China to develop a comprehensive Hardware-in-the-Loop (HIL) simulation test platform for the full topology of OBCs, covering high-frequency two-stage DC/DC circuits and bidirectional three-phase OBC circuits from mass production lines.
When we used traditional simulation platforms to test the OBC three-phase LLC topology, it was difficult to accurately reproduce resonance anomalies under high-frequency switching, with unsatisfactory results. The HIL solution provided by OPAL-RT can stably control the simulation time step within 190 ns (minimum 110 ns), and the capture accuracy of dead-time effects and switching losses can reach 90%.
Engineer at SHINRY
The challenges
- High computation load: LLC + DCDC full-link models need <100 ns time steps, challenging simulator real-time capability.
- Black-box controller risks: Non-transparent control and fast protection logic can trigger false faults from minor model deviations.
- Interface precision: High-frequency signal fidelity, noise immunity, and synchronized multi-channel measurement are critical.
The OPAL-RT solution
To address these challenges, OPAL-RT China deployed a cutting-edge HIL platform powered by the latest FPGA technology:
- Hardware: The OP4800-IO FPGA expansion units, powered by the AMD Versal ACAP platform, provides 10 MSPS Analog Output sampling. This ensures high-fidelity reproduction of LLC current waveforms with a sub-microsecond closed-loop response.
- Software: eHS (FPGA-based power electronics toolbox) uses physical modeling instead of switching-function models, allowing fast topology modification without lengthy HDL recompilation. It supports switching frequencies up to 500 kHz with 625 ps sampling resolution, ensuring high-fidelity simulation of resonant behaviors and switching dynamics
- Automated Testing: Seamless integration with CANoe through open APIs (Python/LabVIEW) enables automated test execution, supports CAN FD up to 8 Mbps, and allows independent control of hundreds of relays for large-scale automated fault injection and validation.
The reuse of automated scripts has saved us a significant amount of repetitive work and greatly reduced manual operations. Previously, testing a single OBC model required at least 30 days; now it’s shortened to 20 days. Both test accuracy and efficiency have achieved qualitative improvements.
Engineer at SHINRY
The results
The OPAL-RT HIL solution transformed SHINRY’s R&D and verification processes:
- Accelerated Development: Reduced the testing cycle for a single OBC model from 30 days to 20 days (a 33% improvement).
- Early Issue Detection: Identified 5 types of hidden software-hardware integration problems before reaching the vehicle testing stage.
- High-Precision Accuracy: Achieved 90% accuracy in capturing dead-time effects and switching losses, with simulation steps as low as 110ns–190ns.
- Comprehensive Test Coverage: Enabled full closed-loop testing for Charge, Precharge, and various V2X modes (V2G, V2L, V2V), ensuring reliability under extreme conditions.
- Scalable & Reusable System: The open interface allowed for the reuse of automated scripts, lowering the barrier to testing and maximizing long-term value.
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FAQ
Find the answers to your questions
Why is real-time EMT simulation challenging for cascaded H-bridge MV VFD topologies?
Cascaded H-bridge systems combine multi-level switching behavior with tightly coupled transformer and rectifier networks, leading to large state counts and heavy computational load. Capturing switching dynamics, phase shifting, and control interactions at real-time rates often requires specialized partitioning methods and FPGA acceleration.
How does the eHS and ARTEMiS hybrid approach enable real-time simulation for complex drives?
In this workflow, high-frequency inverter switching and converter dynamics can be executed on FPGA using eHS, while larger coupled networks such as transformers and rectifiers run efficiently on CPU using ARTEMiS. Multi-rate execution and model decoupling make it possible to maintain fidelity while meeting real-time constraints.
What aspects of MV VFD control algorithms can be validated using HIL?
HIL testing can validate control strategies such as V/f control and vector control for asynchronous and synchronous machines, as well as timing-sensitive behaviors like mode changes, switching sequences, and protection logic. It also supports regression testing to catch control program issues early in development.
Can a single HIL bench support multiple motor types and sensor feedback models?
Yes. A well-configured real-time HIL setup can support multiple motor models—such as induction machines and PMSMs—along with sensor models like incremental encoders and resolvers. This enables broader coverage of customer-site configurations without rebuilding physical test rigs for each scenario.
What kinds of fault and protection tests can be validated in a simulated MV VFD environment?
A real-time simulation environment can be used to verify protection behavior for conditions such as switching events, grounding faults, out-of-phase detection, and bus overvoltage or undervoltage scenarios. This supports safer validation of protection strategies that are costly or risky to test on physical prototypes.
How does OPAL-RT support deployment beyond the hardware and software platform?
OPAL-RT can provide integration support across model development, pre-deployment validation, on-site commissioning assistance, and ongoing technical support. This helps reduce the learning curve for first-time users, shortens debugging timelines, and improves project continuity as requirements evolve.
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