The Engine Controller Hardware-in-the-Loop (HIL) Test System is a next-generation verification platform designed for Full Authority Digital Engine Control (FADEC) systems. By integrating high-fidelity real-time simulation with physical control hardware, it provides a complete test environment for engine electronic controllers (EEC) and engine health management units (EMU). As an indispensable stage in FADEC development, the system enables in-depth validation of control strategies, fault tolerance mechanisms, diagnostic algorithms, and interface circuitry, while supporting closed-loop simulations of engine operation and automated testing processes. This ensures the reliability and safety of future aircraft propulsion systems.

Within the HIL framework, real control units such as the EEC or EMU are placed in a test loop, while the controlled objects—such as engines, sensors, or fuel systems—are modeled on a real-time simulation computer. By incorporating physical I/O interfaces, the platform transforms digital models into real-world compatible simulation environments. This approach allows engineers to replicate fuel system dynamics, sensor signals, actuator responses, and full-flight scenarios, enabling accurate closed-loop validation under near-realistic conditions.

The primary mission of the system is to provide comprehensive verification of FADEC technologies. It validates the correctness of control laws and logic, the robustness of Built-In Test (BIT) and fault recovery strategies, as well as the reliability of interface circuits. With this capability, developers can quickly conduct concept validation and system evaluation in the early stages of design, reducing both risks and costs in the development cycle.

Technically, the system demonstrates significant advantages. Built on the SIVB Integrated Verification Platform, it leverages multi-core real-time simulation technology to achieve high-fidelity semi-physical simulations of complex nonlinear dynamic systems. It supports a wide range of signal types, including LVDT, RVDT, thermocouples, speed, flow, liquid level, discrete signals, and analog signals, accurately replicating real-world sensor and actuator behaviors. Additionally, the platform supports ARINC429, RS422, ARINC664, and Ethernet bus protocols, providing full coverage for modern avionics communication standards.

Functionally, the solution offers a complete end-to-end architecture. The host platform provides resource management, parameter configuration, state monitoring, data recording, replay, and automatic code generation. The real-time simulation system performs mathematical modeling and script execution for engines, sensors, and fuel systems, managing all I/O control channels. The signal conditioning module ensures precise electrical matching between the simulation platform and the controller. A dedicated fault injection system enables simulation of sensor failures, actuator malfunctions, bus communication errors, and power anomalies, validating the fault-tolerant design of EEC/EMU hardware and software. Furthermore, the power simulation unit replicates aircraft power supply conditions under both normal and failure modes, verifying the controller’s stability and resilience.

The platform also features a human-machine interaction system that supports throttle lever operation and intuitive test data visualization, allowing engineers to conduct tests more effectively and interpret results with greater clarity. This not only improves experimental safety and efficiency but also bridges the gap between laboratory conditions and real-world flight environments.

The Engine HIL Verification Solution has already been successfully deployed in the development and testing of CXX-1000 and CXX-2000 engine controllers, proving its engineering adaptability and scalability. As a cornerstone infrastructure for future FADEC research, this solution will continue to drive breakthroughs in engine control technologies and accelerate the progress toward more advanced and autonomous aircraft propulsion systems.