{"id":6665,"date":"2026-07-22T19:50:43","date_gmt":"2026-07-22T19:50:43","guid":{"rendered":"https:\/\/impedyme.com\/?p=6665"},"modified":"2026-07-23T18:05:43","modified_gmt":"2026-07-23T18:05:43","slug":"hil-testing-motor-control","status":"publish","type":"post","link":"https:\/\/impedyme.com\/de\/resource-center\/hil-testing-motor-control\/","title":{"rendered":"HIL Testing for Electric Motor Control"},"content":{"rendered":"\t\t<div data-elementor-type=\"wp-post\" data-elementor-id=\"6665\" class=\"elementor elementor-6665\" data-elementor-post-type=\"post\">\n\t\t\t\t<div class=\"elementor-element elementor-element-c61506b e-con-full elementor-hidden-desktop e-flex e-con e-parent\" data-id=\"c61506b\" data-element_type=\"container\">\n\t\t\t\t<div class=\"elementor-element elementor-element-479e12a elementor-widget elementor-widget-image\" data-id=\"479e12a\" data-element_type=\"widget\" data-widget_type=\"image.default\">\n\t\t\t\t<div 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center;\"><div class=\"custom-category-list\"><div class=\"category-tabs\"><span class=\"category-item\" data-cat=\"12\">Application knowledge<\/span><span class=\"category-item\" data-cat=\"22\">Grid<\/span><span class=\"category-item\" data-cat=\"21\">Motor<\/span><span class=\"category-item\" data-cat=\"13\">Product knowledge<\/span><span class=\"category-item\" data-cat=\"38\">Webinars<\/span><\/div><ul class=\"post-list\" data-cat=\"12\"><li> \n                            <a href=\"https:\/\/impedyme.com\/de\/resource-center\/elevator-motor-drive\/\"> \n                                <span class=\"post-icon\"> \n                                    <img decoding=\"async\" src=\"https:\/\/cdn-icons-png.flaticon.com\/512\/887\/887997.png\" alt=\"Impedyme Document\"> \n                                <\/span> \n                                <span class=\"post-title\" title=\"Elevator Motor Drive\">Elevator Motor Drive<\/span> \n                            <\/a> \n                   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            <span class=\"post-title\" title=\"Solar Inverter Test\">Solar Inverter Test<\/span> \n                            <\/a> \n                          <\/li><li> \n                            <a href=\"https:\/\/impedyme.com\/de\/resource-center\/inverter-test\/\"> \n                                <span class=\"post-icon\"> \n                                    <img decoding=\"async\" src=\"https:\/\/cdn-icons-png.flaticon.com\/512\/887\/887997.png\" alt=\"Impedyme Document\"> \n                                <\/span> \n                                <span class=\"post-title\" title=\"Inverter Test\">Inverter Test<\/span> \n                            <\/a> \n                          <\/li><li> \n                            <a href=\"https:\/\/impedyme.com\/de\/resource-center\/traction-inverter-test\/\"> \n                                <span class=\"post-icon\"> \n                                    <img decoding=\"async\" src=\"https:\/\/cdn-icons-png.flaticon.com\/512\/887\/887997.png\" alt=\"Impedyme Document\"> \n                                <\/span> \n                                <span class=\"post-title\" title=\"Traction Inverter Test\">Traction Inverter Test<\/span> \n                            <\/a> \n                          <\/li><li> \n                            <a href=\"https:\/\/impedyme.com\/de\/resource-center\/hil-test-pfc-converter\/\"> \n                                <span class=\"post-icon\"> \n                                    <img decoding=\"async\" src=\"https:\/\/cdn-icons-png.flaticon.com\/512\/887\/887997.png\" alt=\"Impedyme Document\"> \n                                <\/span> \n                                <span class=\"post-title\" title=\"Controller HIL Testing of Power Factor Correction Converters\">Controller HIL Testing of Power Factor Correction &#8230;<\/span> \n                            <\/a> \n                          <\/li><li> \n                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   <span class=\"post-title\" title=\"Electric Aircraft HIL Testing\">Electric Aircraft HIL Testing<\/span> \n                            <\/a> \n                          <\/li><li> \n                            <a href=\"https:\/\/impedyme.com\/de\/resource-center\/hil-testing-bms\/\"> \n                                <span class=\"post-icon\"> \n                                    <img decoding=\"async\" src=\"https:\/\/cdn-icons-png.flaticon.com\/512\/887\/887997.png\" alt=\"Impedyme Document\"> \n                                <\/span> \n                                <span class=\"post-title\" title=\"HIL Testing of BMS\">HIL Testing of BMS<\/span> \n                            <\/a> \n                          <\/li><li> \n                            <a href=\"https:\/\/impedyme.com\/de\/resource-center\/hil-testing-ev-powertrain\/\"> \n                                <span class=\"post-icon\"> \n                                    <img decoding=\"async\" src=\"https:\/\/cdn-icons-png.flaticon.com\/512\/887\/887997.png\" alt=\"Impedyme Document\"> \n                                <\/span> \n                                <span class=\"post-title\" title=\"Hardware in the Loop Testing for EV Powertrain\">Hardware in the Loop Testing for EV Powertrain<\/span> \n                            <\/a> \n                          <\/li><li> \n                            <a href=\"https:\/\/impedyme.com\/de\/resource-center\/hil-testing-microgrid-renewable\/\"> \n                                <span class=\"post-icon\"> \n                                    <img decoding=\"async\" src=\"https:\/\/cdn-icons-png.flaticon.com\/512\/887\/887997.png\" alt=\"Impedyme Document\"> \n                                <\/span> \n                                <span class=\"post-title\" title=\"Hardware in the Loop Testing for Microgrids and Renewable Energy Systems\">Hardware in the Loop Testing for Microgrids and Re&#8230;<\/span> \n                            <\/a> \n                          <\/li><li> \n                            <a href=\"https:\/\/impedyme.com\/de\/resource-center\/battery-module-testing\/\"> \n                                <span class=\"post-icon\"> \n                                    <img decoding=\"async\" src=\"https:\/\/cdn-icons-png.flaticon.com\/512\/887\/887997.png\" alt=\"Impedyme Document\"> \n                                <\/span> \n                                <span class=\"post-title\" title=\"Battery Module Testing: Ensuring Performance, Safety, and Reliability\">Battery Module Testing: Ensuring Performance, Safe&#8230;<\/span> \n                            <\/a> \n                          <\/li><li> \n                            <a href=\"https:\/\/impedyme.com\/de\/resource-center\/battery-cell-testing\/\"> \n                                <span class=\"post-icon\"> \n                                    <img decoding=\"async\" src=\"https:\/\/cdn-icons-png.flaticon.com\/512\/887\/887997.png\" alt=\"Impedyme Document\"> \n                                <\/span> \n                                <span class=\"post-title\" title=\"Battery Cell Testing: Standards, and Modern Test Systems\">Battery Cell Testing: Standards, and Modern Test S&#8230;<\/span> \n                            <\/a> \n                          <\/li><li> \n                            <a href=\"https:\/\/impedyme.com\/de\/resource-center\/hvdc-power-grid\/\"> \n                                <span class=\"post-icon\"> \n                                    <img decoding=\"async\" src=\"https:\/\/cdn-icons-png.flaticon.com\/512\/887\/887997.png\" alt=\"Impedyme Document\"> \n                                <\/span> \n                                <span class=\"post-title\" title=\"HVDC Power Grid: How High-Voltage Direct Current Transmission\">HVDC Power Grid: How High-Voltage Direct Current T&#8230;<\/span> \n                            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src=\"https:\/\/cdn-icons-png.flaticon.com\/512\/887\/887997.png\" alt=\"Impedyme Document\"> \n                                <\/span> \n                                <span class=\"post-title\" title=\"Battery Management System Testing: Ensuring Safe, Reliable Batteries\">Battery Management System Testing: Ensuring Safe, &#8230;<\/span> \n                            <\/a> \n                          <\/li><li> \n                            <a href=\"https:\/\/impedyme.com\/de\/resource-center\/data-center-power-stability\/\"> \n                                <span class=\"post-icon\"> \n                                    <img decoding=\"async\" src=\"https:\/\/cdn-icons-png.flaticon.com\/512\/887\/887997.png\" alt=\"Impedyme Document\"> \n                                <\/span> \n                                <span class=\"post-title\" title=\"AI Data Center Power Stability: Power Capacitor Shelves, PCS Module Design\">AI Data Center Power Stability: Power Capacitor Sh&#8230;<\/span> \n                            <\/a> \n                          <\/li><li> \n                            <a href=\"https:\/\/impedyme.com\/de\/resource-center\/dc-fast-charger-for-ev\/\"> \n                                <span class=\"post-icon\"> \n                                    <img decoding=\"async\" src=\"https:\/\/cdn-icons-png.flaticon.com\/512\/887\/887997.png\" alt=\"Impedyme Document\"> \n                                <\/span> \n                                <span class=\"post-title\" title=\"DC Fast Charger for EV Battery\">DC Fast Charger for EV Battery<\/span> \n                            <\/a> \n                          <\/li><li> \n                            <a href=\"https:\/\/impedyme.com\/de\/powershelf-testing-data-center\/\"> \n                                <span class=\"post-icon\"> \n                                    <img decoding=\"async\" src=\"https:\/\/cdn-icons-png.flaticon.com\/512\/887\/887997.png\" alt=\"Impedyme Document\"> \n                                <\/span> \n                                <span class=\"post-title\" title=\"Data Center Powershelf Testing with Grid Emulator and DC Load\u200b\">Data Center Powershelf Testing with Grid Emulator &#8230;<\/span> \n                            <\/a> \n                          <\/li><li> \n                            <a href=\"https:\/\/impedyme.com\/de\/resource-center\/derisking-hyperscale-data-center-interconnection\/\"> \n                                <span class=\"post-icon\"> \n                                    <img decoding=\"async\" src=\"https:\/\/cdn-icons-png.flaticon.com\/512\/887\/887997.png\" alt=\"Impedyme Document\"> \n                                <\/span> \n                                <span class=\"post-title\" title=\"De-Risking Hyperscale Data Center Interconnections Through Simulation-First Grid Stability Planning\">De-Risking Hyperscale Data Center Interconnections&#8230;<\/span> \n                            <\/a> \n                          <\/li><li> \n                            <a href=\"https:\/\/impedyme.com\/de\/resource-center\/phil-grid-forming\/\"> \n                                <span class=\"post-icon\"> \n                                    <img decoding=\"async\" src=\"https:\/\/cdn-icons-png.flaticon.com\/512\/887\/887997.png\" alt=\"Impedyme Document\"> \n                                <\/span> \n                                <span class=\"post-title\" title=\"Megawatt-Scale Testing Grid Forming with PHIL: Advanced Power Hardware-in-the-Loop Validation\">Megawatt-Scale Testing Grid Forming with PHIL: Adv&#8230;<\/span> \n                            <\/a> \n                          <\/li><li> \n                            <a href=\"https:\/\/impedyme.com\/de\/resource-center\/power-grid-stability\/\"> \n                                <span class=\"post-icon\"> \n                                    <img decoding=\"async\" src=\"https:\/\/cdn-icons-png.flaticon.com\/512\/887\/887997.png\" alt=\"Impedyme Document\"> \n                                <\/span> \n                                <span class=\"post-title\" title=\"Stabilizing Renewable Power Systems and Enhancing Power Grid Stability with Grid Forming Inverters\">Stabilizing Renewable Power Systems and Enhancing &#8230;<\/span> \n                            <\/a> \n                          <\/li><li> \n                            <a href=\"https:\/\/impedyme.com\/de\/resource-center\/webinars\/\"> \n                                <span class=\"post-icon\"> \n                                    <img decoding=\"async\" src=\"https:\/\/cdn-icons-png.flaticon.com\/512\/887\/887997.png\" alt=\"Impedyme Document\"> \n                                <\/span> \n                                <span class=\"post-title\" title=\"Webinars\">Webinars<\/span> \n                            <\/a> \n                          <\/li><li> \n                    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     <\/span> \n                                <span class=\"post-title\" title=\"Motor Emulation for Humanoid Robots Motor Drive Testing\">Motor Emulation for Humanoid Robots Motor Drive Te&#8230;<\/span> \n                            <\/a> \n                          <\/li><li> \n                            <a href=\"https:\/\/impedyme.com\/de\/resource-center\/emc-compliance-test-solutions\/\"> \n                                <span class=\"post-icon\"> \n                                    <img decoding=\"async\" src=\"https:\/\/cdn-icons-png.flaticon.com\/512\/887\/887997.png\" alt=\"Impedyme Document\"> \n                                <\/span> \n                                <span class=\"post-title\" title=\"EMC Compliance Test Solutions\">EMC Compliance Test Solutions<\/span> \n                            <\/a> \n                          <\/li><li> \n                            <a href=\"https:\/\/impedyme.com\/de\/variable-frequency-drive-testing\/\"> \n                 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Test and Power Quality Solution\">Your Harmonic Test and Power Quality Solution<\/span> \n                            <\/a> \n                          <\/li><li> \n                            <a href=\"https:\/\/impedyme.com\/de\/resource-center\/real-time-grid-impedance-modeling\/\"> \n                                <span class=\"post-icon\"> \n                                    <img decoding=\"async\" src=\"https:\/\/cdn-icons-png.flaticon.com\/512\/887\/887997.png\" alt=\"Impedyme Document\"> \n                                <\/span> \n                                <span class=\"post-title\" title=\"Real Time Grid Impedance Modeling with FPGA Integration\">Real Time Grid Impedance Modeling with FPGA Integr&#8230;<\/span> \n                            <\/a> \n                          <\/li><li> \n                            <a href=\"https:\/\/impedyme.com\/de\/resource-center\/high-voltage-dc-current-ai-server\/\"> \n                                <span class=\"post-icon\"> 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Test\">Inverter Test<\/span> \n                            <\/a> \n                          <\/li><li> \n                            <a href=\"https:\/\/impedyme.com\/de\/resource-center\/traction-inverter-test\/\"> \n                                <span class=\"post-icon\"> \n                                    <img decoding=\"async\" src=\"https:\/\/cdn-icons-png.flaticon.com\/512\/887\/887997.png\" alt=\"Impedyme Document\"> \n                                <\/span> \n                                <span class=\"post-title\" title=\"Traction Inverter Test\">Traction Inverter Test<\/span> \n                            <\/a> \n                          <\/li><li> \n                            <a href=\"https:\/\/impedyme.com\/de\/resource-center\/hil-testing-ev-powertrain\/\"> \n                                <span class=\"post-icon\"> \n                                    <img decoding=\"async\" src=\"https:\/\/cdn-icons-png.flaticon.com\/512\/887\/887997.png\" alt=\"Impedyme 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      <\/a> \n                          <\/li><li> \n                            <a href=\"https:\/\/impedyme.com\/de\/resource-center\/pmsm-rotor-angular-velocity\/\"> \n                                <span class=\"post-icon\"> \n                                    <img decoding=\"async\" src=\"https:\/\/cdn-icons-png.flaticon.com\/512\/887\/887997.png\" alt=\"Impedyme Document\"> \n                                <\/span> \n                                <span class=\"post-title\" title=\"PMSM Rotor Angular Velocity\">PMSM Rotor Angular Velocity<\/span> \n                            <\/a> \n                          <\/li><li> \n                            <a href=\"https:\/\/impedyme.com\/de\/resource-center\/pmsm-based-electrical-traction-drive\/\"> \n                                <span class=\"post-icon\"> \n                                    <img decoding=\"async\" src=\"https:\/\/cdn-icons-png.flaticon.com\/512\/887\/887997.png\" alt=\"Impedyme Document\"> \n                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href=\"https:\/\/impedyme.com\/de\/resource-center\/synchronous-machine-based-electrical-drive-simulation\/\"> \n                                <span class=\"post-icon\"> \n                                    <img decoding=\"async\" src=\"https:\/\/cdn-icons-png.flaticon.com\/512\/887\/887997.png\" alt=\"Impedyme Document\"> \n                                <\/span> \n                                <span class=\"post-title\" title=\"Synchronous Machine-Based Electrical Drive Simulation\">Synchronous Machine-Based Electrical Drive Simulat&#8230;<\/span> \n                            <\/a> \n                          <\/li><\/ul><ul class=\"post-list\" data-cat=\"13\"><li> \n                            <a href=\"https:\/\/impedyme.com\/de\/powerhardware-in-the-loop\/\"> \n                                <span class=\"post-icon\"> \n                                    <img decoding=\"async\" src=\"https:\/\/cdn-icons-png.flaticon.com\/512\/887\/887997.png\" alt=\"Impedyme Document\"> \n                                <\/span> \n                                <span class=\"post-title\" title=\"Purpose and Role of Power Hardware in the Loop (PHIL) Simulation\">Purpose and Role of Power Hardware in the Loop (PH&#8230;<\/span> \n                            <\/a> \n                          <\/li><li> \n                            <a href=\"https:\/\/impedyme.com\/de\/optimizing-grid-connected-converters-for-stability\/\"> \n                                <span class=\"post-icon\"> \n                                    <img decoding=\"async\" src=\"https:\/\/cdn-icons-png.flaticon.com\/512\/887\/887997.png\" alt=\"Impedyme Document\"> \n                                <\/span> \n                                <span class=\"post-title\" title=\"Optimizing Grid-Connected Converters for Stability\">Optimizing Grid-Connected Converters for Stability<\/span> \n                            <\/a> \n                          <\/li><li> \n                            <a href=\"https:\/\/impedyme.com\/de\/unlocking-insights-into-power-system-stability\/\"> \n                                <span class=\"post-icon\"> \n                                    <img decoding=\"async\" src=\"https:\/\/cdn-icons-png.flaticon.com\/512\/887\/887997.png\" alt=\"Impedyme Document\"> \n                                <\/span> \n                                <span class=\"post-title\" title=\"Unlocking Insights into Power System Stability\">Unlocking Insights into Power System Stability<\/span> \n                            <\/a> \n                          <\/li><\/ul><ul class=\"post-list\" data-cat=\"38\"><li> \n                            <a href=\"https:\/\/impedyme.com\/de\/resource-center\/webinars\/\"> \n                                <span class=\"post-icon\"> \n                                    <img decoding=\"async\" src=\"https:\/\/cdn-icons-png.flaticon.com\/512\/887\/887997.png\" alt=\"Impedyme Document\"> \n                                <\/span> \n                                <span class=\"post-title\" title=\"Webinars\">Webinars<\/span> \n                            <\/a> \n                          <\/li><\/ul><\/div><\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t<div class=\"elementor-element elementor-element-4d92924 e-con-full e-flex e-con e-child\" data-id=\"4d92924\" data-element_type=\"container\">\n\t\t\t\t<div class=\"elementor-element elementor-element-1793840 elementor-hidden-tablet elementor-hidden-mobile elementor-widget elementor-widget-image\" data-id=\"1793840\" data-element_type=\"widget\" data-widget_type=\"image.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<img decoding=\"async\" width=\"1024\" height=\"464\" src=\"https:\/\/impedyme.com\/wp-content\/uploads\/2026\/07\/hil-testing-for-electric-motor-header-1024x464.webp\" class=\"attachment-large size-large wp-image-6677\" alt=\"hil testing for electric motor header\" srcset=\"https:\/\/impedyme.com\/wp-content\/uploads\/2026\/07\/hil-testing-for-electric-motor-header-1024x464.webp 1024w, https:\/\/impedyme.com\/wp-content\/uploads\/2026\/07\/hil-testing-for-electric-motor-header-300x136.webp 300w, https:\/\/impedyme.com\/wp-content\/uploads\/2026\/07\/hil-testing-for-electric-motor-header-768x348.webp 768w, https:\/\/impedyme.com\/wp-content\/uploads\/2026\/07\/hil-testing-for-electric-motor-header-1536x696.webp 1536w, https:\/\/impedyme.com\/wp-content\/uploads\/2026\/07\/hil-testing-for-electric-motor-header-18x8.webp 18w, https:\/\/impedyme.com\/wp-content\/uploads\/2026\/07\/hil-testing-for-electric-motor-header-150x68.webp 150w, https:\/\/impedyme.com\/wp-content\/uploads\/2026\/07\/hil-testing-for-electric-motor-header-480x217.webp 480w, https:\/\/impedyme.com\/wp-content\/uploads\/2026\/07\/hil-testing-for-electric-motor-header.webp 2020w\" sizes=\"(max-width:767px) 480px, (max-width:1024px) 100vw, 1024px\" \/>\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-7a5674d elementor-widget elementor-widget-heading\" data-id=\"7a5674d\" data-element_type=\"widget\" data-widget_type=\"heading.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t<h1 class=\"elementor-heading-title elementor-size-default\">HIL Testing for Electric Motor Control \n<\/h1>\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-2b8ca7b elementor-widget elementor-widget-text-editor\" data-id=\"2b8ca7b\" data-element_type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t<p style=\"text-align: center;\">[custom_toc]<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-d7905b2 elementor-widget elementor-widget-text-editor\" data-id=\"d7905b2\" data-element_type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t<p><span style=\"font-weight: 400;\">Electric motor control has quietly become one of the most important disciplines in modern engineering. According to the IEA 4E Electric Motor Systems Platform (EMSA) Policy Brief, &#8220;In 2023, electric motor systems were responsible for 53% of global electricity consumption.&#8221; This guide explains how <a href=\"https:\/\/impedyme.com\/hardware-in-the-loop\">HIL testing<\/a> for electric motor control lets engineers validate PMSM controllers safely, earlier, and faster using FPGA-based real-time simulation \u2014 and how Impedyme&#8217;s ecosystem of hardware and software brings the entire workflow into one platform.<\/span><\/p><h2>Why Electric Motor Control Deserves Better Testing<\/h2><p><span style=\"font-weight: 400;\">Electric motors are the invisible workhorses of the modern world. They move vehicles, drive factory lines, circulate air in buildings, pump water on farms, and spin the compressors inside nearly every appliance. As electrification accelerates across transportation, industry, and energy, the software and power electronics that control these motors have become the decisive factor in efficiency, reliability, and safety.<\/span><\/p><p><span style=\"font-weight: 400;\">Two forces are pushing motor control engineering harder than ever. The first is the relentless drive for energy-efficient power electronics. The IEA 4E EMSA Policy Brief breaks the picture down by sector: &#8220;Their share in electricity consumption varies widely across sectors: 72% in industry, 36% in buildings, 87% in agriculture and 86% in the transportation sector.&#8221; When motors dominate electricity use to that degree, even small gains in inverter and controller efficiency scale into enormous energy and emissions savings.<\/span><\/p><p><span style=\"font-weight: 400;\">The second force is the rise of smart controller software. A modern <a href=\"https:\/\/impedyme.com\/resource-center\/permanent-magnet-synchronous-machine\/\">permanent magnet synchronous motor (PMSM)<\/a> drive runs sophisticated <a href=\"https:\/\/impedyme.com\/resource-center\/field-oriented-control\/\">field-oriented control (FOC)<\/a> algorithms, manages thermal limits, coordinates regenerative braking, and executes safety functions \u2014 all in real time, on an embedded controller, at switching frequencies that keep climbing as wide-bandgap semiconductors (SiC and GaN) become mainstream.<\/span><\/p><p><span style=\"font-weight: 400;\">The problem is that testing this software the old way \u2014 on a physical motor, a dynamometer, or in the field \u2014 is slow, expensive, and often dangerous. That is where hardware-in-the-loop (HIL) testing for electric motor control transforms the development process.<\/span><\/p><h2>What Is HIL Testing for Electric Motor Control?<\/h2><p><span style=\"font-weight: 400;\">Hardware-in-the-loop testing is a real-time simulation approach in which the actual controller hardware runs production or production-intent software while interacting with a simulated physical system. Instead of connecting your motor controller to a real motor and inverter, you connect it to a real-time target that mathematically emulates the motor, the inverter, and the sensors \u2014 reproducing the electrical and timing behavior the controller expects.<\/span><\/p><p><span style=\"font-weight: 400;\">The controller under test \u2014 the device under test, or DUT \u2014 cannot tell the difference. It sends PWM switching commands to what it believes is a real inverter, and it receives back motor currents, DC-link voltage, and rotor position exactly as a physical machine would produce them. The result is a closed loop that behaves like a bench or field test but without exposing expensive equipment or people to harm.<\/span><\/p><p><span style=\"font-weight: 400;\">For electric motor control specifically, there are two closely related techniques:<\/span><\/p><ul><li style=\"font-weight: 400;\" aria-level=\"1\"><b>Controller HIL (signal-level testing):<\/b><span style=\"font-weight: 400;\"> The embedded controller is tested against a virtual PMSM and inverter running on a real-time target. All exchange happens at the signal level \u2014 low-voltage analog and digital I\/O. No real power flows.<\/span><\/li><li style=\"font-weight: 400;\" aria-level=\"1\"><b>Power HIL (PHIL, power-level testing):<\/b><span style=\"font-weight: 400;\"> A power stage is added so real voltage and current flow between the emulator and the device under test. A motor emulator sources and sinks genuine current, so a physical inverter can be validated at full power without a physical motor or dynamometer.<\/span><\/li><\/ul><p><span style=\"font-weight: 400;\">Impedyme builds its entire platform around this progression \u2014 from signal to power \u2014 using FPGA-based real-time targets that eliminate the latency bottlenecks of traditional processor-based systems.<\/span><\/p><h2>Why Engineers Move to Real-Time HIL Testing<\/h2><p><span style=\"font-weight: 400;\">The motivation for adopting HIL testing for electric motor control comes down to six concrete advantages.<\/span><\/p><h4><span style=\"color: #d18100;\">1. Test Safely Without Damaging Equipment<\/span><\/h4><p><span style=\"font-weight: 400;\">Shorting an inverter leg, forcing an overcurrent, or spinning a motor past its rated speed on a real bench can destroy hardware and injure people. In simulation, these events are just numbers. A simulated short circuit repeats exactly, so you can verify trip handling and recovery logic as many times as you want with zero risk to physical motors, inverters, or batteries.<\/span><a href=\"https:\/\/www.opal-rt.com\/blog\/when-fpga-real-time-simulation-makes-sense-for-power-electronics-hil\/\"><span style=\"font-weight: 400;\">\u00a0<\/span><\/a><\/p><h4><span style=\"color: #d18100;\">2. Test Earlier in the Development Cycle<\/span><\/h4><p><span style=\"font-weight: 400;\">With HIL, you can begin validating control firmware and protection logic as soon as a controller exists \u2014 long before a full power prototype, a motor sample, or a dyno cell is available. This catches the cheapest-to-fix defects first, when they are inexpensive to correct.<\/span><a href=\"https:\/\/impedyme.com\/resource-center\/inverter-testing\"><span style=\"font-weight: 400;\">\u00a0<\/span><\/a><\/p><h4><span style=\"color: #d18100;\">3. Reduce Iteration Loops and Time to Market<\/span><\/h4><p><span style=\"font-weight: 400;\">Every physical test cycle \u2014 build, wire, instrument, run, tear down \u2014 costs days. HIL collapses those loops into minutes. Because the plant is software-defined, engineers change a motor parameter or a fault scenario with a mouse click rather than a rewiring job.<\/span><\/p><h4><span style=\"color: #d18100;\">4. Ensure Compliance With Requirements and Regulations<\/span><\/h4><p><span style=\"font-weight: 400;\">Motor drives must satisfy functional requirements, EMC limits, and functional-safety standards. HIL provides a repeatable, traceable environment where each requirement can be linked to a test case and verified automatically, generating the documentation that certification demands.<\/span><\/p><h4><span style=\"color: #d18100;\">5. Isolate the Device Under Test<\/span><\/h4><p><span style=\"font-weight: 400;\">HIL reduces the test to just the controller and its software, simulating the complete environment around it. The test becomes a clean black-box test at the controller&#8217;s pins, so a failure points unambiguously at the controller rather than at a noisy, uncontrolled physical rig.<\/span><a href=\"https:\/\/www.elektormagazine.com\/news\/hardware-in-the-loop-and-continuous-integration-how-do-they-fit-together\"><span style=\"font-weight: 400;\">\u00a0<\/span><\/a><\/p><h4><span style=\"color: #d18100;\">6. Automate Testing and Improve Edge-Case Coverage<\/span><\/h4><p><span style=\"font-weight: 400;\">Because the plant is deterministic and the bench is safe, tests can run unsupervised, overnight, and around the clock. Engineers can sweep the entire torque-speed map and inject rare faults that would be impractical or dangerous to reproduce physically \u2014 dramatically expanding coverage.<\/span><\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-49072d9 elementor-widget elementor-widget-image\" data-id=\"49072d9\" data-element_type=\"widget\" data-widget_type=\"image.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<img decoding=\"async\" width=\"1024\" height=\"576\" src=\"https:\/\/impedyme.com\/wp-content\/uploads\/2026\/07\/motor-control-hil-testing-1024x576.webp\" class=\"attachment-large size-large wp-image-6671\" alt=\"motor control hil testing\" srcset=\"https:\/\/impedyme.com\/wp-content\/uploads\/2026\/07\/motor-control-hil-testing-1024x576.webp 1024w, https:\/\/impedyme.com\/wp-content\/uploads\/2026\/07\/motor-control-hil-testing-300x169.webp 300w, https:\/\/impedyme.com\/wp-content\/uploads\/2026\/07\/motor-control-hil-testing-768x432.webp 768w, https:\/\/impedyme.com\/wp-content\/uploads\/2026\/07\/motor-control-hil-testing-1536x864.webp 1536w, https:\/\/impedyme.com\/wp-content\/uploads\/2026\/07\/motor-control-hil-testing-2048x1152.webp 2048w, https:\/\/impedyme.com\/wp-content\/uploads\/2026\/07\/motor-control-hil-testing-18x10.webp 18w, https:\/\/impedyme.com\/wp-content\/uploads\/2026\/07\/motor-control-hil-testing-133x75.webp 133w, https:\/\/impedyme.com\/wp-content\/uploads\/2026\/07\/motor-control-hil-testing-480x270.webp 480w\" sizes=\"(max-width:767px) 480px, (max-width:1024px) 100vw, 1024px\" \/>\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-84c72d1 elementor-widget elementor-widget-text-editor\" data-id=\"84c72d1\" data-element_type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t<h2><span style=\"color: #000000;\">The Complete Workflow: From Desktop Simulation to Full Power<\/span><\/h2><p><span style=\"font-weight: 400;\">Impedyme structures motor control validation as a continuous workflow with three stages. The power of the approach is that the same models and test assets carry forward at every stage, so engineers never have to rewrite their work when they move from simulation to hardware.<\/span><\/p><p>\n<table id=\"tablepress-121\" class=\"tablepress tablepress-id-121\">\n<thead>\n<tr class=\"row-1\">\n\t<th class=\"column-1\">Stage<\/th><th class=\"column-2\">What It Validates<\/th><th class=\"column-3\">Impedyme Platform<\/th>\n<\/tr>\n<\/thead>\n<tbody class=\"row-striping row-hover\">\n<tr class=\"row-2\">\n\t<td class=\"column-1\">Desktop simulation<\/td><td class=\"column-2\">Control algorithm logic and model behavior \u2014 offline, no power, no physical motor<\/td><td class=\"column-3\">Model-based design tools + Impedyme Simulink Blockset<\/td>\n<\/tr>\n<tr class=\"row-3\">\n\t<td class=\"column-1\">Controller HIL (signal-level)<\/td><td class=\"column-2\">Embedded controller firmware against a virtual PMSM and inverter \u2014 low-voltage signals only, no physical motor<\/td><td class=\"column-3\">CHP Series \/ RCP-Box + MotorSim Studio<\/td>\n<\/tr>\n<tr class=\"row-4\">\n\t<td class=\"column-1\">Power HIL (PHIL)<\/td><td class=\"column-2\">Controller and power stage at full traction power via motor emulation \u2014 real power flows, but the motor is emulated<\/td><td class=\"column-3\">CHP Series motor emulator + PowerHIL Studio<\/td>\n<\/tr>\n<tr class=\"row-5\">\n\t<td class=\"column-1\">Dynamometer \/ mechanical<\/td><td class=\"column-2\">Final system under real mechanical load \u2014 full power plus mechanical, physical motor required<\/td><td class=\"column-3\">Dynamometer testbench<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<\/p><h3><span style=\"color: #d18100;\">Stage 1: Desktop Simulation<\/span><\/h3><p><span style=\"font-weight: 400;\">Engineers first build high-fidelity models of the controller and the plant \u2014 the PMSM and inverter \u2014 in a desktop simulation environment. Here the control algorithm is developed and refined virtually, before any hardware is involved. This is where a reference behavior is established that later HIL tests will be compared against.<\/span><\/p><h3><span style=\"color: #d18100;\">Stage 2: Controller HIL Against a Virtual PMSM<\/span><\/h3><p><span style=\"font-weight: 400;\">Next, the embedded controller becomes the device under test. The motor and inverter models are deployed to an FPGA-based real-time target \u2014 an <a href=\"https:\/\/impedyme.com\/chp-series\/\">Impedyme CHP Series system<\/a> or <a href=\"https:\/\/impedyme.com\/rcp-box\/\">HIL\/RCP-Box<\/a> \u2014 running MotorSim Studio. The controller runs its real firmware and interacts with the virtual motor in a closed loop at microsecond time steps.<\/span><\/p><h3><span style=\"color: #d18100;\">Stage 3: Power HIL With Motor Emulation<\/span><\/h3><p><span style=\"font-weight: 400;\">Finally, testing moves into the power domain. <a href=\"https:\/\/impedyme.com\/powerhardware-in-the-loop\/\">Impedyme&#8217;s PHIL<\/a> capability adds a regenerative power interface \u2014 a high-bandwidth power amplifier co-designed with the FPGA real-time core \u2014 that turns the simulated motor into real current and voltage. A physical inverter is now driven by an emulated motor that sources and sinks genuine power, with no physical machine or dynamometer required. This is where component stress, thermal behavior, and full-power protection are validated.<\/span><\/p><h3>Inside a PMSM Controller HIL Test: A Walkthrough<\/h3><p><span style=\"font-weight: 400;\">To make the concept concrete, consider a representative controller HIL test of a PMSM drive, genericized to the Impedyme ecosystem.<\/span><\/p><p><span style=\"font-weight: 400;\">The device under test is an embedded motor controller running a field-oriented control algorithm. It is wired to an Impedyme CHP Series real-time target instead of a real motor and inverter. The closed loop works like this:<\/span><\/p><ul><li style=\"font-weight: 400;\" aria-level=\"1\"><b>Speed command in:<\/b><span style=\"font-weight: 400;\"> A speed reference is sent to the controller over the CAN bus \u2014 the same interface it would use in a vehicle.<\/span><\/li><li style=\"font-weight: 400;\" aria-level=\"1\"><b>PWM capture:<\/b><span style=\"font-weight: 400;\"> The controller&#8217;s PWM outputs are captured by the high-speed digital inputs of the real-time target at nanosecond resolution.<\/span><\/li><li style=\"font-weight: 400;\" aria-level=\"1\"><b>Motor emulation:<\/b><span style=\"font-weight: 400;\"> The FPGA runs the inverter and PMSM models, computing the resulting phase currents in real time.<\/span><\/li><li style=\"font-weight: 400;\" aria-level=\"1\"><b>Current feedback:<\/b><span style=\"font-weight: 400;\"> The simulated motor currents are fed back to the controller through the target&#8217;s analog outputs, exactly as current sensors would provide.<\/span><\/li><li style=\"font-weight: 400;\" aria-level=\"1\"><b>Position feedback:<\/b><span style=\"font-weight: 400;\"> Rotor position is returned via quadrature encoder emulation, so the FOC algorithm receives the angle it needs to run correctly in the rotating reference frame.<\/span><a href=\"https:\/\/www.mathworks.com\/help\/mcb\/ref\/quadraturedecoder.html\"><span style=\"font-weight: 400;\">\u00a0<\/span><\/a><\/li><\/ul><p><span style=\"font-weight: 400;\">From the controller&#8217;s perspective, a real motor is spinning. Engineers watch it command a speed, see the virtual motor accelerate, and observe balanced three-phase currents develop \u2014 all on screen, with no rotating mass anywhere in the lab.<\/span><\/p><h3>Requirements Traceability<\/h3><p><span style=\"font-weight: 400;\">A disciplined HIL test starts from named requirements and ends with numeric checks. In this walkthrough, two example requirements illustrate the idea:<\/span><a href=\"https:\/\/www.opal-rt.com\/blog\/building-a-regression-testing-pipeline-for-hil-in-electrification-teams\/\"><span style=\"font-weight: 400;\">\u00a0<\/span><\/a><\/p><ul><li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">A speed limit requirement \u2014 for instance, the drive must not exceed 5,000 RPM.<\/span><\/li><li style=\"font-weight: 400;\" aria-level=\"1\"><span style=\"font-weight: 400;\">A balanced-operation requirement \u2014 the three phase currents must remain balanced during normal operation.<\/span><\/li><\/ul><p><span style=\"font-weight: 400;\">Each requirement maps to a test case with defined initial conditions, stimulus, and pass criteria. When the automated test runs, it verifies the requirement and records the result, creating the traceable evidence chain that validation and certification teams need.<\/span><\/p><h2><span style=\"color: #000000;\">Ideal (Averaged) Inverter Model vs. FPGA Switching-Level Model<\/span><\/h2><p><span style=\"font-weight: 400;\">One of the most important decisions in motor control HIL is how to model the inverter. There are two fundamentally different approaches, and choosing correctly determines whether your test reveals real behavior or hides it.<\/span><\/p><p><span style=\"font-weight: 400;\">An <\/span><b>averaged (ideal) inverter model<\/b><span style=\"font-weight: 400;\"> represents the inverter using controlled voltage sources that reproduce the average behavior over a PWM period. It is computationally cheap and runs comfortably on a CPU at relatively coarse time steps. It is excellent for validating slow dynamics \u2014 speed loops, DC-bus energy balance, system-level coordination \u2014 where the fine detail of switching is irrelevant.<\/span><\/p><p><span style=\"font-weight: 400;\">A <\/span><b>switching-level inverter model<\/b><span style=\"font-weight: 400;\"> represents each semiconductor switch explicitly. It reproduces the actual on\/off transitions, and therefore the current ripple, torque ripple, dead-time distortion, and switching harmonics that a real inverter produces. This detail is essential when you are developing the control for the inverter itself, or when protection logic trips on instantaneous peak currents rather than filtered averages. The catch is that it demands a very small time step \u2014 which is exactly why an FPGA is required.<\/span><span style=\"font-weight: 400;\">\u00a0<\/span><\/p><p>\n<table id=\"tablepress-122\" class=\"tablepress tablepress-id-122\">\n<thead>\n<tr class=\"row-1\">\n\t<th class=\"column-1\">Attribute<\/th><th class=\"column-2\">Averaged (Ideal) Inverter Model<\/th><th class=\"column-3\">FPGA Switching-Level Inverter Model<\/th>\n<\/tr>\n<\/thead>\n<tbody class=\"row-striping row-hover\">\n<tr class=\"row-2\">\n\t<td class=\"column-1\">Switch representation<\/td><td class=\"column-2\">Controlled voltage sources (averaged)<\/td><td class=\"column-3\">Each semiconductor modeled explicitly<\/td>\n<\/tr>\n<tr class=\"row-3\">\n\t<td class=\"column-1\">Typical execution<\/td><td class=\"column-2\">CPU, coarse time step<\/td><td class=\"column-3\">FPGA, sub-microsecond time step<\/td>\n<\/tr>\n<tr class=\"row-4\">\n\t<td class=\"column-1\">Current ripple visible?<\/td><td class=\"column-2\">No \u2014 muted by averaging<\/td><td class=\"column-3\">Yes \u2014 reproduced faithfully<\/td>\n<\/tr>\n<tr class=\"row-5\">\n\t<td class=\"column-1\">Torque ripple visible?<\/td><td class=\"column-2\">No<\/td><td class=\"column-3\">Yes<\/td>\n<\/tr>\n<tr class=\"row-6\">\n\t<td class=\"column-1\">Switching harmonics \/ EMC insight<\/td><td class=\"column-2\">No<\/td><td class=\"column-3\">Yes<\/td>\n<\/tr>\n<tr class=\"row-7\">\n\t<td class=\"column-1\">Instantaneous peak-current faults<\/td><td class=\"column-2\">Missed<\/td><td class=\"column-3\">Captured<\/td>\n<\/tr>\n<tr class=\"row-8\">\n\t<td class=\"column-1\">Best for<\/td><td class=\"column-2\">Speed loops, system-level dynamics<\/td><td class=\"column-3\">Inverter control, protection, ripple, EMC<\/td>\n<\/tr>\n<tr class=\"row-9\">\n\t<td class=\"column-1\">Computational cost<\/td><td class=\"column-2\">Low<\/td><td class=\"column-3\">High (requires FPGA parallelism)<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-f8a69a7 elementor-widget elementor-widget-image\" data-id=\"f8a69a7\" data-element_type=\"widget\" data-widget_type=\"image.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<img loading=\"lazy\" decoding=\"async\" width=\"1024\" height=\"576\" src=\"https:\/\/impedyme.com\/wp-content\/uploads\/2026\/07\/hil-testing-for-motor-control-1024x576.webp\" class=\"attachment-large size-large wp-image-6670\" alt=\"hil testing for motor control\" srcset=\"https:\/\/impedyme.com\/wp-content\/uploads\/2026\/07\/hil-testing-for-motor-control-1024x576.webp 1024w, https:\/\/impedyme.com\/wp-content\/uploads\/2026\/07\/hil-testing-for-motor-control-300x169.webp 300w, https:\/\/impedyme.com\/wp-content\/uploads\/2026\/07\/hil-testing-for-motor-control-768x432.webp 768w, https:\/\/impedyme.com\/wp-content\/uploads\/2026\/07\/hil-testing-for-motor-control-1536x864.webp 1536w, https:\/\/impedyme.com\/wp-content\/uploads\/2026\/07\/hil-testing-for-motor-control-2048x1152.webp 2048w, https:\/\/impedyme.com\/wp-content\/uploads\/2026\/07\/hil-testing-for-motor-control-18x10.webp 18w, https:\/\/impedyme.com\/wp-content\/uploads\/2026\/07\/hil-testing-for-motor-control-133x75.webp 133w, https:\/\/impedyme.com\/wp-content\/uploads\/2026\/07\/hil-testing-for-motor-control-480x270.webp 480w\" sizes=\"(max-width:767px) 480px, (max-width:1024px) 100vw, 1024px\" \/>\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-5c45d41 elementor-widget elementor-widget-text-editor\" data-id=\"5c45d41\" data-element_type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t<h3><span style=\"color: #000000;\">Why the FPGA Matters<\/span><\/h3><p><span style=\"font-weight: 400;\">An averaged model on a CPU will slow down until ripple and peak currents are muted, and hardware protection that would trip on a real bench misses the same trigger in simulation \u2014 leaving teams tuning around a simulator artifact instead of a real control issue. The FPGA solves this because it co-locates computation and I\/O on the same chip, eliminating bus-transfer latency.<\/span><a href=\"https:\/\/impedyme.com\/rcp-box\"><span style=\"font-weight: 400;\">\u00a0<\/span><\/a><\/p><p><span style=\"font-weight: 400;\">In an Impedyme FPGA-based real-time target, PWM gate edges are captured at nanosecond-scale resolution \u2014 on the order of a few nanoseconds \u2014 while the motor and inverter model updates at approximately one microsecond, driven by an FPGA clock running at roughly 200 MHz. Impedyme&#8217;s CHP platform pushes model updates as fast as 90 nanoseconds, performing hundreds to over a thousand updates per electrical period. That temporal resolution is what allows the emulated motor to reproduce saturation, cross-coupling, torque ripple, and back-EMF harmonics faithfully.<\/span><a href=\"https:\/\/impedyme.com\/resource-center\/inverter-testing\"><span style=\"font-weight: 400;\">\u00a0<\/span><\/a><\/p><p><span style=\"font-weight: 400;\">The stakes are quantitative. Impedyme notes that a 25-microsecond simulation loop reproducing an 8 kHz PWM can introduce up to 20% error, while sub-microsecond time steps cut that error to under 1%. In motor control, that difference is the line between a test you can trust and one you cannot.<\/span><\/p><h3><span style=\"color: #d18100;\">Observing Ripple, Harmonics, and EMC Behavior<\/span><\/h3><p><span style=\"font-weight: 400;\">Once the switching-level model is running, engineers can use Impedyme FPGA Scope to observe the signals that matter. FPGA Scope is a built-in, high-speed visualization tool embedded directly in the real-time signal path, capable of monitoring up to 16 simultaneous channels \u2014 phase currents, dq-axis currents, phase voltages, PWM edges, and internal controller states \u2014 at sub-microsecond resolution, without any external oscilloscope or DAQ hardware.<\/span><a href=\"https:\/\/impedyme.com\/fpga-scope\/\"><span style=\"font-weight: 400;\">\u00a0<\/span><\/a><\/p><p><span style=\"font-weight: 400;\">With the switching model, current ripple appears as the small high-frequency oscillation superimposed on the fundamental current waveform. This ripple is a direct consequence of the PWM switching acting on the motor&#8217;s winding inductance. It drives torque ripple, which in turn causes noise, vibration, and additional losses.<\/span><\/p><p><span style=\"font-weight: 400;\">Engineers can run harmonic analysis on the captured waveforms to quantify the distortion and understand its spectral content \u2014 critical for anticipating electromagnetic compatibility (EMC) problems before they show up in an EMC lab. The high-frequency content that a switching-level model reveals is precisely the content that averaged models delete by construction, and precisely the content that determines EMI behavior.<\/span><\/p><h3><span style=\"color: #d18100;\">Mitigation: Increasing the PWM Switching Frequency<\/span><\/h3><p><span style=\"font-weight: 400;\">A classic mitigation is to raise the PWM switching frequency. Current ripple is inversely proportional to switching frequency: increasing the frequency shortens the interval over which current can drift between switching events, so the ripple shrinks. This inverse relationship is well established \u2014 as an illustrative example, a CERN technical report on high-precision power converters notes that raising switching frequency &#8220;from 5kHz that is currently used, up to 60kHz and beyond \u2026 gives an increase in accuracy by an order of magnitude or more.&#8221; Raising a drive&#8217;s PWM frequency to 20 kHz \u2014 above the audible range \u2014 reduces current ripple, smooths torque, lowers audible whine, and cuts harmonic content, at the cost of higher switching losses.<\/span><a href=\"https:\/\/www.portescap.com\/en\/newsroom\/whitepapers\/2022\/03\/controlling-brushed-dc-motors-using-pwm\"><span style=\"font-weight: 400;\">\u00a0<\/span><\/a><\/p><p><span style=\"font-weight: 400;\">Because HIL makes this a software change rather than a hardware rebuild, engineers can sweep the PWM frequency, observe the improvement in ripple and harmonics in real time on FPGA Scope, and find the optimal trade-off between ripple, losses, and thermal stress \u2014 all in a single afternoon.<\/span><\/p><h3><span style=\"color: #d18100;\">Electrical Fault Injection Testing<\/span><\/h3><p><span style=\"font-weight: 400;\">Some of the most valuable HIL tests are the ones you could never safely run on real hardware. Fault-injection HIL is built to answer one question: what does the controller do when conditions break normal limits?<\/span><\/p><p><span style=\"font-weight: 400;\">For a PMSM drive, the critical fault scenarios include short circuits in the inverter legs, phase loss, DC-link collapse, overcurrent events, over-speed, and sensor failures. On a physical bench, forcing a short circuit through an inverter leg stresses devices, varies run to run, and risks catastrophic damage. In HIL, the same fault is a scripted, perfectly repeatable event.<\/span><\/p><p>\n<table id=\"tablepress-123\" class=\"tablepress tablepress-id-123\">\n<thead>\n<tr class=\"row-1\">\n\t<th class=\"column-1\">Fault Scenario<\/th><th class=\"column-2\">What It Tests<\/th><th class=\"column-3\">Why HIL Is Superior<\/th>\n<\/tr>\n<\/thead>\n<tbody class=\"row-striping row-hover\">\n<tr class=\"row-2\">\n\t<td class=\"column-1\">Inverter leg short circuit<\/td><td class=\"column-2\">Overcurrent protection, shoot-through response<\/td><td class=\"column-3\">Destroys real hardware; safe and repeatable in HIL<\/td>\n<\/tr>\n<tr class=\"row-3\">\n\t<td class=\"column-1\">Overcurrent event<\/td><td class=\"column-2\">Current-limit and trip thresholds<\/td><td class=\"column-3\">Precise, timed injection without device stress<\/td>\n<\/tr>\n<tr class=\"row-4\">\n\t<td class=\"column-1\">Phase loss \/ open circuit<\/td><td class=\"column-2\">Fallback and ride-through logic<\/td><td class=\"column-3\">Hard to stage physically; trivial in simulation<\/td>\n<\/tr>\n<tr class=\"row-5\">\n\t<td class=\"column-1\">DC-link voltage sag<\/td><td class=\"column-2\">Low-voltage restart and control margin<\/td><td class=\"column-3\">Dangerous at power; deterministic in HIL<\/td>\n<\/tr>\n<tr class=\"row-6\">\n\t<td class=\"column-1\">Over-speed<\/td><td class=\"column-2\">Speed-limit enforcement<\/td><td class=\"column-3\">Risk of mechanical failure on real motor<\/td>\n<\/tr>\n<tr class=\"row-7\">\n\t<td class=\"column-1\">Sensor \/ resolver fault<\/td><td class=\"column-2\">Fault detection and safe-state entry<\/td><td class=\"column-3\">Repeatable at exact timestamps<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<\/p><p><span style=\"font-weight: 400;\">A typical scripted scenario shows the power of the approach: the test runs normally, then at exactly 5 seconds a short-circuit fault is injected. The controller&#8217;s protection logic should detect the overcurrent and shut off the PWM within its specified response time. Because the fault triggers on a timestamp and the plant is deterministic, the test verifies not only that protection fires, but that it fires fast enough and recovers cleanly \u2014 every single run.<\/span><\/p><p><span style=\"font-weight: 400;\">This is impossible or prohibitively dangerous with real hardware, but straightforward and safe with HIL. It is one of the strongest arguments for adopting HIL testing for electric motor control.<\/span><\/p><h3><span style=\"color: #d18100;\">Test Automation and Continuous Integration<\/span><\/h3><p><span style=\"font-weight: 400;\">The final piece of the workflow is automation. Once a HIL bench is safe and deterministic, motor control testing can join the same continuous-integration (CI) practices that software teams have used for decades \u2014 something that was traditionally impossible for power electronics because lab testing was too slow and expensive to run on every code commit.<\/span><\/p><p><span style=\"font-weight: 400;\">With <a href=\"https:\/\/impedyme.com\/powerhil-studio\/\">Impedyme PowerHIL Studio<\/a> orchestrating the bench, engineers can build automated test campaigns using a scenario and sequence editor: drive cycles, ramps, step changes, and fault scenarios, with automated pass\/fail criteria and reporting of key metrics such as current ripple, torque ripple, efficiency, and protection response. PowerHIL Studio also enforces built-in safety and limit management with configurable current, voltage, and power limits and controlled shutdown.<\/span><\/p><p><span style=\"font-weight: 400;\">A mature motor control CI workflow looks like this:<\/span><\/p><ul><li style=\"font-weight: 400;\" aria-level=\"1\"><b>Baseline comparison:<\/b><span style=\"font-weight: 400;\"> Each HIL run is compared against the desktop simulation reference, with a defined tolerance \u2014 for example, results must match the reference within 10%.<\/span><\/li><li style=\"font-weight: 400;\" aria-level=\"1\"><b>Requirements verification:<\/b><span style=\"font-weight: 400;\"> Every named requirement is checked automatically and linked back to its test case.<\/span><\/li><li style=\"font-weight: 400;\" aria-level=\"1\"><b>Commit-triggered testing:<\/b><span style=\"font-weight: 400;\"> When a developer commits new control firmware, the CI system automatically builds it, deploys it to the controller, and runs the HIL test suite \u2014 providing feedback in minutes instead of weeks.<\/span><a href=\"https:\/\/www.typhoon-hil.com\/blog\/continuous-integration-with-hil-fully-automate-power-electronics-control-software-testing\/\"><span style=\"font-weight: 400;\">\u00a0<\/span><\/a><\/li><li style=\"font-weight: 400;\" aria-level=\"1\"><b>Regression testing:<\/b><span style=\"font-weight: 400;\"> The full suite runs on every change, catching unintended side effects and ensuring that a fix in one area does not break behavior elsewhere across the product lifecycle.<\/span><a href=\"https:\/\/www.typhoon-hil.com\/support\/services\/test-automation\/\"><span style=\"font-weight: 400;\">\u00a0<\/span><\/a><\/li><\/ul><p><span style=\"font-weight: 400;\">Because the tests are scripted and the bench is safe, the whole suite runs unsupervised. Test execution that once took weeks in a power lab can complete in under an hour, and the same test assets remain valid from the earliest signal-level testing through full-power PHIL validation.<\/span><a href=\"https:\/\/www.elektormagazine.com\/news\/hardware-in-the-loop-and-continuous-integration-how-do-they-fit-together\"><span style=\"font-weight: 400;\">\u00a0<\/span><\/a><\/p><h2>The Impedyme Ecosystem for Motor Control HIL<\/h2><p><span style=\"font-weight: 400;\">What makes this workflow seamless is that Impedyme delivers every piece as an integrated ecosystem, so models and test assets flow from desktop simulation to full power without being rewritten.<\/span><\/p><ul><li style=\"font-weight: 400;\" aria-level=\"1\"><b>CHP Series real-time targets:<\/b><span style=\"font-weight: 400;\"> FPGA-based HIL\/PHIL platforms \u2014 the CHP 150 half-cabinet and CHP 300 full-cabinet \u2014 combining signal-level HIL and full-power, regenerative PHIL in one architecture, with simulation time steps as low as 90 nanoseconds and multi-channel analog, digital, and fiber I\/O.<\/span><\/li><li style=\"font-weight: 400;\" aria-level=\"1\"><b><a href=\"https:\/\/impedyme.com\/electric-motor-simulation-software\/\">MotorSim Studio<\/a>:<\/b><span style=\"font-weight: 400;\"> The high-fidelity motor and drive emulation environment, with model libraries for PMSM, induction, BLDC, and IPM machines, supporting nonlinear effects like magnetic saturation, hysteresis, and torque ripple, plus angle-dependent flux and torque maps.<\/span><\/li><li style=\"font-weight: 400;\" aria-level=\"1\"><b>PowerHIL Studio:<\/b><span style=\"font-weight: 400;\"> The orchestration and automation layer that configures hardware, scripts test campaigns, coordinates multi-emulator setups, and generates reports \u2014 all from a single MATLAB-integrated environment.<\/span><\/li><li style=\"font-weight: 400;\" aria-level=\"1\"><b><a href=\"https:\/\/impedyme.com\/fpga-scope\/\">FPGA Scope<\/a>:<\/b><span style=\"font-weight: 400;\"> Built-in, sub-microsecond signal visualization with up to 16 channels and trigger-based capture, embedded directly in the FPGA signal path \u2014 no external instruments required.<\/span><\/li><li style=\"font-weight: 400;\" aria-level=\"1\"><b>HIL\/RCP-Box:<\/b><span style=\"font-weight: 400;\"> A compact rapid control prototyping platform with a user-programmable Ultrascale+ FPGA and dual-core ARM processor, closed-loop control up to 250 kHz, resolver\/encoder interfaces, and CAN\/CAN-FD \u2014 ideal for early-stage controller development and signal-level motor emulation.<\/span><a href=\"https:\/\/impedyme.com\/rcp-box\"><span style=\"font-weight: 400;\">\u00a0<\/span><\/a><\/li><li style=\"font-weight: 400;\" aria-level=\"1\"><b>Impedyme-RT:<\/b><span style=\"font-weight: 400;\"> The real-time engine that connects model-based design tools directly to the hardware, with automatic code generation and one-click deployment to CPU, FPGA, or hybrid execution.<\/span><a href=\"https:\/\/impedyme.com\/rcp-box\"><span style=\"font-weight: 400;\">\u00a0<\/span><\/a><\/li><\/ul><p><span style=\"font-weight: 400;\">Together these components enable <a href=\"https:\/\/impedyme.com\/technology\/\">Combined Hardware-in-the-Loop and Power (CHP)<\/a> testing, letting engineers validate control logic and power electronics simultaneously.<\/span><\/p><p><span style=\"font-weight: 400;\">This same platform extends naturally to adjacent validation challenges. Teams working on motor control HIL often also need <a href=\"https:\/\/impedyme.com\/resource-center\/hil-testing-bms\/\">BMS HIL testing<\/a> for battery management systems, full EV powertrain HIL for system-level validation, and inverter testing at full traction power \u2014 all of which run on the same CHP Series hardware and software ecosystem.<\/span><\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-8ccf541 elementor-widget elementor-widget-image\" data-id=\"8ccf541\" data-element_type=\"widget\" data-widget_type=\"image.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<img loading=\"lazy\" decoding=\"async\" width=\"1024\" height=\"576\" src=\"https:\/\/impedyme.com\/wp-content\/uploads\/2026\/07\/electric-motor-hil-test-1024x576.webp\" class=\"attachment-large size-large wp-image-6668\" alt=\"electric motor hil test\" srcset=\"https:\/\/impedyme.com\/wp-content\/uploads\/2026\/07\/electric-motor-hil-test-1024x576.webp 1024w, https:\/\/impedyme.com\/wp-content\/uploads\/2026\/07\/electric-motor-hil-test-300x169.webp 300w, https:\/\/impedyme.com\/wp-content\/uploads\/2026\/07\/electric-motor-hil-test-768x432.webp 768w, https:\/\/impedyme.com\/wp-content\/uploads\/2026\/07\/electric-motor-hil-test-1536x864.webp 1536w, https:\/\/impedyme.com\/wp-content\/uploads\/2026\/07\/electric-motor-hil-test-2048x1152.webp 2048w, https:\/\/impedyme.com\/wp-content\/uploads\/2026\/07\/electric-motor-hil-test-18x10.webp 18w, https:\/\/impedyme.com\/wp-content\/uploads\/2026\/07\/electric-motor-hil-test-133x75.webp 133w, https:\/\/impedyme.com\/wp-content\/uploads\/2026\/07\/electric-motor-hil-test-480x270.webp 480w\" sizes=\"(max-width:767px) 480px, (max-width:1024px) 100vw, 1024px\" \/>\t\t\t\t\t\t\t\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-c444cab elementor-widget elementor-widget-text-editor\" data-id=\"c444cab\" data-element_type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t<h2>Signal-Level vs. Power-Level vs. Dynamometer: Choosing the Right Stage<\/h2><p><span style=\"font-weight: 400;\">A common question is when to use each testing stage. The answer is that they are complementary, not competing, and the right program uses all of them in sequence.<\/span><\/p><p>\n<table id=\"tablepress-125\" class=\"tablepress tablepress-id-125\">\n<thead>\n<tr class=\"row-1\">\n\t<th class=\"column-1\">Method<\/th><th class=\"column-2\">Fidelity<\/th><th class=\"column-3\">Cost &amp; Safety<\/th><th class=\"column-4\">Best Use<\/th>\n<\/tr>\n<\/thead>\n<tbody class=\"row-striping row-hover\">\n<tr class=\"row-2\">\n\t<td class=\"column-1\">Desktop simulation<\/td><td class=\"column-2\">Model-level only<\/td><td class=\"column-3\">Lowest cost, no risk<\/td><td class=\"column-4\">Algorithm design, early logic checks<\/td>\n<\/tr>\n<tr class=\"row-3\">\n\t<td class=\"column-1\">Controller HIL (signal)<\/td><td class=\"column-2\">High timing fidelity, no power<\/td><td class=\"column-3\">Low cost, very safe<\/td><td class=\"column-4\">Firmware, protection logic, fault injection<\/td>\n<\/tr>\n<tr class=\"row-4\">\n\t<td class=\"column-1\">Power HIL (PHIL)<\/td><td class=\"column-2\">Full electrical fidelity at power<\/td><td class=\"column-3\">Moderate cost, safe (emulated)<\/td><td class=\"column-4\">Power-stage stress, thermal, full-power protection<\/td>\n<\/tr>\n<tr class=\"row-5\">\n\t<td class=\"column-1\">Dynamometer<\/td><td class=\"column-2\">Full mechanical fidelity<\/td><td class=\"column-3\">High cost, real hazards<\/td><td class=\"column-4\">Final system validation, efficiency mapping<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<\/p><p><span style=\"font-weight: 400;\">The guiding principle is to start at the signal level early, move to PHIL for power-stage and envelope coverage once the power stage is available, and reserve the dynamometer for final mechanical validation. Making FPGA-based, microsecond-or-faster time-step fidelity a hard requirement ensures that coarse simulation never misrepresents switching behavior along the way.<\/span><a href=\"https:\/\/impedyme.com\/resource-center\/inverter-testing\"><span style=\"font-weight: 400;\">\u00a0<\/span><\/a><\/p><h3><span style=\"color: #000000;\">How to Build a Motor Control HIL Program<\/span><\/h3><p><span style=\"font-weight: 400;\">Based on the workflow above, here is a staged, actionable path \u2014 and the benchmarks that should govern each decision.<\/span><\/p><ol><li style=\"font-weight: 400;\" aria-level=\"1\"><b>Start at the signal level as soon as a controller exists.<\/b><span style=\"font-weight: 400;\"> Deploy your PMSM and inverter models to an FPGA-based controller HIL target (Impedyme RCP-Box or CHP Series with MotorSim Studio) and validate FOC firmware, CAN command handling, and protection logic. <\/span><i><span style=\"font-weight: 400;\">Benchmark to advance:<\/span><\/i><span style=\"font-weight: 400;\"> HIL results match your desktop simulation reference within your chosen tolerance (e.g., 10%) across the core operating points.<\/span><\/li><li style=\"font-weight: 400;\" aria-level=\"1\"><b>Insist on FPGA-based, switching-level fidelity from day one.<\/b><span style=\"font-weight: 400;\"> If your inverter model is averaged and running on a CPU, it will mute the ripple and peak currents your protection logic depends on. <\/span><i><span style=\"font-weight: 400;\">Threshold that should change your approach:<\/span><\/i><span style=\"font-weight: 400;\"> if PWM-loop error approaches the ~20% seen at coarse (25 \u00b5s) time steps, move to a sub-microsecond FPGA model before trusting any protection or ripple result.<\/span><\/li><li style=\"font-weight: 400;\" aria-level=\"1\"><b>Build a fault-injection library early.<\/b><span style=\"font-weight: 400;\"> Script inverter-leg shorts, phase loss, DC-link sag, overcurrent, over-speed, and sensor faults as timestamped, repeatable events. <\/span><i><span style=\"font-weight: 400;\">Benchmark:<\/span><\/i><span style=\"font-weight: 400;\"> every safety requirement has a corresponding fault test that confirms both the trip and a clean recovery.<\/span><\/li><li style=\"font-weight: 400;\" aria-level=\"1\"><b>Automate and wire into CI.<\/b><span style=\"font-weight: 400;\"> Once the bench is safe and deterministic, trigger the HIL suite on every firmware commit and run full regression nightly. <\/span><i><span style=\"font-weight: 400;\">Benchmark:<\/span><\/i><span style=\"font-weight: 400;\"> full-suite execution under one hour with automatic baseline comparison and requirements traceability.<\/span><\/li><li style=\"font-weight: 400;\" aria-level=\"1\"><b>Move to PHIL for power-stage coverage.<\/b><span style=\"font-weight: 400;\"> When the physical inverter is available, bring it into a closed-loop PHIL bench with motor emulation to sweep the full torque-speed map and validate thermal and full-power protection behavior. <\/span><i><span style=\"font-weight: 400;\">Benchmark:<\/span><\/i><span style=\"font-weight: 400;\"> full-envelope coverage achieved before committing to dynamometer or vehicle testing.<\/span><\/li><li style=\"font-weight: 400;\" aria-level=\"1\"><b>Reserve the dynamometer for final mechanical validation only.<\/b><span style=\"font-weight: 400;\"> By the time a design reaches the dyno, HIL and PHIL should have already closed out control, protection, and envelope risks \u2014 leaving the expensive, hazardous mechanical stage for confirmation rather than discovery.<\/span><\/li><\/ol><h2>Conclusion<\/h2><p><span style=\"font-weight: 400;\">HIL testing for electric motor control has evolved from a nice-to-have into the central gate for validating PMSM drives. It lets engineers test safely, test earlier, iterate faster, ensure compliance, isolate the controller, and automate coverage of edge cases that no physical bench could safely reproduce. The key enabler is FPGA-based real-time simulation, which alone can reproduce the switching-level ripple, torque ripple, and fault behavior that determine whether a drive is genuinely ready for production.<\/span><\/p><p><span style=\"font-weight: 400;\">Impedyme brings the entire workflow \u2014 desktop simulation, controller HIL, and full-power PHIL \u2014 into one integrated ecosystem built around the CHP Series, MotorSim Studio, PowerHIL Studio, FPGA Scope, RCP-Box, and Impedyme-RT. The result is faster development, safer validation, and higher-fidelity results from the first line of control code to the final full-power test.<\/span><\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-d78cd6c elementor-widget elementor-widget-text-editor\" data-id=\"d78cd6c\" data-element_type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t<h3><span style=\"font-weight: 400;\">Frequently Asked Questions\u00a0<\/span><\/h3><p><b>What is HIL testing for electric motor control?<\/b><\/p><p><span style=\"font-weight: 400;\">HIL (hardware-in-the-loop) testing for electric motor control is a real-time simulation method in which an embedded motor controller runs its real software while interacting with a virtual PMSM and inverter running on a real-time target. The controller sends PWM commands and receives simulated currents and rotor position, forming a closed loop that behaves like a real motor drive without any physical motor.<\/span><\/p><p><b>What is the difference between an averaged and a switching-level inverter model?<\/b><\/p><p><span style=\"font-weight: 400;\">An averaged inverter model represents the inverter with controlled voltage sources and captures only average behavior, making it cheap to run but blind to ripple and switching harmonics. A switching-level model represents each semiconductor switch explicitly, reproducing current ripple, torque ripple, and harmonics \u2014 essential for inverter control development, protection testing, and EMC analysis. Switching-level models require FPGA execution.<\/span><\/p><p><b>How does HIL testing handle inverter fault injection?<\/b><\/p><p><span style=\"font-weight: 400;\">HIL lets engineers inject faults such as inverter-leg short circuits, phase loss, overcurrent, DC-link sag, and over-speed as scripted, perfectly repeatable events. For example, a short circuit can be triggered at exactly 5 seconds to verify that the controller&#8217;s overcurrent protection shuts off the PWM within its specified time. These tests are dangerous or impossible on real hardware but safe and repeatable in HIL.<\/span><\/p><p><b>Can motor control HIL testing be automated for continuous integration?<\/b><\/p><p><span style=\"font-weight: 400;\">Yes. With PowerHIL Studio, test campaigns can be scripted with automated pass\/fail criteria, compared against desktop simulation baselines within defined tolerances (such as 10%), and triggered automatically when developers commit new firmware. This brings continuous integration and regression testing to power electronics, reducing test cycles from weeks to under an hour.<\/span><\/p><p><b>What is the difference between HIL and Power HIL (PHIL) for motor drives?<\/b><\/p><p><span style=\"font-weight: 400;\">Controller HIL tests the embedded controller at the signal level against a virtual motor, with no real power flowing. Power HIL (PHIL) adds a regenerative power interface so real voltage and current flow between an emulated motor and a physical inverter, enabling full-power validation of the power stage without a physical motor or dynamometer.<\/span><\/p><p><b>Which Impedyme products are used for PMSM controller HIL testing?<\/b><\/p><p><span style=\"font-weight: 400;\">PMSM controller HIL testing on the Impedyme platform uses the CHP Series or RCP-Box FPGA-based real-time targets, MotorSim Studio for high-fidelity motor emulation, PowerHIL Studio for test orchestration and automation, FPGA Scope for sub-microsecond signal monitoring, and Impedyme-RT to connect model-based design tools to the hardware.<\/span><\/p>\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<div class=\"elementor-element elementor-element-1cbeb78 elementor-align-center elementor-widget__width-inherit elementor-widget elementor-widget-button\" data-id=\"1cbeb78\" data-element_type=\"widget\" data-rp-stop=\"true\" data-widget_type=\"button.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t<div class=\"elementor-button-wrapper\">\n\t\t\t\t\t<a class=\"elementor-button elementor-button-link elementor-size-sm\" href=\"https:\/\/impedyme.com\/contact\/\">\n\t\t\t\t\t\t<span class=\"elementor-button-content-wrapper\">\n\t\t\t\t\t\t\t\t\t<span class=\"elementor-button-text\">Request a Demo<\/span>\n\t\t\t\t\t<\/span>\n\t\t\t\t\t<\/a>\n\t\t\t\t<\/div>\n\t\t\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t<div class=\"elementor-element elementor-element-57472ea e-con-full e-flex e-con e-child\" data-id=\"57472ea\" data-element_type=\"container\">\n\t\t\t\t<div class=\"elementor-element elementor-element-885d9ad elementor-widget elementor-widget-text-editor\" data-id=\"885d9ad\" data-element_type=\"widget\" data-widget_type=\"text-editor.default\">\n\t\t\t\t<div class=\"elementor-widget-container\">\n\t\t\t\t\t\t\t\t\t<!-- ============================================================\n     RELATED PRODUCTS \u2014 sticky sidebar (follows scroll, then stops\n     at the \"Request a Demo\" button). 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