Control Hardware in the Loop Testing of High Power DC DC Converters

Relevance

Control-Hardware-in-the-Loop (CHIL) testing has emerged as a crucial methodology for validating the control systems of power electronics without requiring full-scale prototypes. As the demand for reliable and efficient power conversion increases, the complexity of control strategies grows in order to ensure stability, robustness, and fast dynamic response under varying operating conditions. Conventional hardware testing is often costly, time-intensive, and limited by safety concerns, highlighting the need for advanced testing approaches.

By integrating real-time digital simulation with actual control hardware, CHIL provides a safe and cost-effective testing environment that accelerates development cycles and enhances design reliability. For high-power DC-DC converters in particular, CHIL enables thorough validation of fault scenarios, transient behavior, and grid-support functionalities, thereby bridging the gap between simulation and field deployment.

Abstract

This building block provides practical insights into the workflow and methodology of controller development for power electronics. It introduces Control-Hardware-in-the-Loop (CHiL) testing, outlines its core use cases, and explains why it is such a powerful approach for software development. Different code development techniques are then presented, with a detailed comparison of their applicability in both industrial and research contexts. Furthermore, a broad range of generalized testing methods is covered, enabling engineers to effectively validate and verify developed code. The theoretical foundation of this building block is drawn from real-world industrial experience in developing production-ready code and can be generalized and directly applied to the engineer’s workflow. Finally, the laboratory exercise provides hands-on opportunities to investigate and debug existing firmware in preparation for CHiL commissioning—an essential step prior