Many teams today want the benefits of hardware-in-the-loop testing but without the cost, lead times, and overhead associated with traditional HIL rigs. For one OEM, the challenge was clear: how do we validate ECUs early, cheaply, and flexibly - without building a full lab?

With a combination of RemotiveLabs’ cloud-native simulation platform, Kvaser’s reliable PCIe and USB hardware, and ECM’s custom-built test racks, the team created an accessible hybrid setup that supports both SIL and HIL workflows. The result is a controlled, developer-friendly environment that teams can run directly from their desks.

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The challenge: validation without the full HIL burden

Modern HIL setups need to observe and stimulate multiple vehicle networks: CAN, LIN, FlexRay, UART, J1708/1587, Ethernet, each adding layers of configuration. Commercial HIL systems are powerful, but they come with two major drawbacks:

• High entry costs, with proprietary hardware and licenses
• Limited flexibility, as shared rigs slow iteration and lock teams into fixed architectures

As one engineer put it: “It’s too complicated and too expensive for what we need.” For smaller teams, or for development phases that don’t require a full physical rig, the barriers are simply too high.

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The solution: lightweight, reproducible hybrid racks

To support day-to-day ECU development and feature testing, the OEM built 30 automated test racks, each equipped with 3–4 Kvaser cards and a Linux-based control computer. The racks integrate virtual nodes from RemotiveTopology with physical hardware through Kvaser’s interfaces, creating a hybrid SIL/HIL environment that can be spun up quickly and reused across projects. What they used: 

‍Kvaser: Components that gave the customer accurate, cost-efficient hardware that can be repurposed across teams.

• PCIe 8-channel boards
• Hybrid CAN/LIN USB interfaces
• CANlib and SocketCAN support
• LIN responder simulation
• (Upcoming) Kvaser Arcus media converter

RemotiveLabs: RemotiveTopology ensures the same development approach could be used across virtual and physical tests - reducing silos and removing the boundary between SIL and HIL.

• Provide integrated environment to run virtual ECUs with various levels of fidelity
• Support for mixing SIL and HIL in the same environment
• Standard Linux tools and CI/CD integration
• CLI-first workflows for fast iteration
• API enabling Python-based automation on Linux

EMC AB: Supplied the test racks and integration help to the OEM including Kvaser & RemotiveLabs tooling according to the specification.

• Designed and delivered the physical racks
• Built Linux-based industrial computers that connected all Kvaser hardware
• Ensured the full setup matched the OEM’s spec and test needs - a hybrid, modular rig that can grow with the team’s needs.

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Together, these technologies allow teams to test ECUs and vehicle functions in hybrid environments, mixing virtual and physical components seamlessly.

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Key benefits

• ‍Fast startup Linux-based tooling and open drivers meant engineers could get running without proprietary roadblocks.‍
• Reusable hardware PCIe boards and interfaces can be moved between racks or projects as needed - reducing long-term risk.‍
• Desk-level validation Most tests no longer require a full HIL rig; engineers can validate functionality from a laptop or desktop.‍
• Scalable by design Start small with a focused setup and scale toward broader HIL scenarios as the project grows.‍
• Consistent workflows SIL and HIL follow the same development and testing logic, lowering cognitive load and avoiding duplicated work.