Expert Engineering Consulting & Technical Analysis Services
Expert engineering guidance tailored to your specific needs with strategic insights and innovative solutions
Advanced Engineering Solutions for Complex Systems
Specialized engineering consulting in electrical design, controls systems, data acquisition, simulation, and system-level hardware testbeds. With deep automotive expertise in Vehicle-in-the-Loop (VIL) and Hardware-in-the-Loop (HIL) testing.
The automotive HIL testing market is growing at 10.86% CAGR, reaching $4.2 billion by 2032 driven by electric vehicles and autonomous systems development.
Our Engineering Consulting Services
Electrical Design
Complete electrical system design from power distribution to control circuits. We design robust, scalable electrical architectures for automotive, industrial, and research applications with comprehensive documentation and compliance standards.
Controls Design
Advanced control system development including PLC programming, SCADA implementation, HMI design, and real-time control algorithms. From concept to commissioning with full system integration.
Data Acquisition Systems
High-performance data acquisition solutions for real-time monitoring, analysis, and control. Custom sensor integration, signal conditioning, and data logging systems for research and production environments.
Simulation & Modeling
Physics-based simulation models for system validation and optimization. MATLAB/Simulink development, real-time simulation, and model-based design for complex engineering systems.
Hardware Testbeds
System-level hardware testbed design and implementation for comprehensive testing and validation. From component-level testing to full system integration and validation.
Automotive Testing Excellence
Leading expertise in vehicle-level testing with dynamometer-based HIL systems for ECU validation and vehicle dynamics simulation
Vehicle-in-the-Loop (VIL) Testing
Complete vehicle dynamics simulation integrated with real ECUs and control systems. Real-time vehicle model execution with dynamometer integration for comprehensive drivetrain testing.
Hardware-in-the-Loop (HIL) Testing
Advanced HIL systems for ECU validation with real-time simulation of vehicle subsystems. Support for ADAS, powertrain, and body electronics testing with ISO 26262 compliance.
ECU Testing & Validation
Comprehensive electronic control unit testing from function-level validation to system integration. Automated test execution with fault injection and boundary condition testing.
Vehicle Dynamics Simulation
High-fidelity vehicle dynamics models for accurate simulation of handling, braking, acceleration, and environmental conditions. Real-time execution on dSPACE and National Instruments platforms.
Dynamometer Integration
Expert integration of AC/DC dynamometers with simulation systems for powertrain testing. Load simulation, regenerative testing, and efficiency mapping for electric and hybrid vehicles.
Scalable Simulation Architecture
Modular, scalable simulation systems that grow with your testing requirements. Cloud-enabled distributed testing with remote monitoring and control capabilities.
Advanced Hardware Testbed Solutions
Challenge: Automotive OEM needed comprehensive ECU testing for hybrid powertrain development
Our Solution: Complete HIL testbed with real-time vehicle dynamics and dynamometer load simulation
- Real-time engine and electric motor models executing on dSPACE SCALEXIO
- AC dynamometer integration for realistic load simulation
- ECU network simulation with CAN/FlexRay/Ethernet protocols
- Automated test execution with fault injection capabilities
- Battery management system integration and testing
- Thermal management system simulation
Results: 65% reduction in physical prototype testing, 80% faster ECU validation, 40% cost savings in development cycle
Challenge: Tier 1 supplier required comprehensive ADAS ECU testing with sensor fusion validation
Our Solution: Multi-domain HIL system with sensor simulation and scenario-based testing
- Camera, radar, and LiDAR sensor simulation with IPG CarMaker
- V2X communication testing with dedicated short-range communications
- Real-time traffic scenario simulation with OpenDRIVE/OpenSCENARIO
- Ethernet backbone for high-bandwidth sensor data streaming
- Integration with steering, braking, and acceleration actuators
- Safety case validation according to ISO 26262 ASIL-D requirements
Results: 10,000+ test scenarios executed, 95% test automation, 99.9% system availability
Challenge: EV startup needed comprehensive testing solution for motor controller and battery management
Our Solution: Integrated HIL/VIL system with high-voltage safety and thermal simulation
- Motor/inverter HIL testing with Typhoon HIL real-time simulator
- Battery pack simulation with cell-level modeling and thermal effects
- Charging system testing with AC/DC charging protocols
- Functional safety testing with emergency shutdown sequences
- Vehicle-level range and efficiency optimization testing
- Regenerative braking system validation
Results: 50% reduction in battery testing time, 30% improvement in range accuracy, Zero safety incidents during testing
Challenge: Manufacturing facility needed comprehensive testing of automated production line controls
Our Solution: Digital twin testbed with real-time process simulation and operator training
- Complete production line digital twin with physics-based modeling
- Real PLC and SCADA system integration testing
- Human-machine interface (HMI) validation and operator training
- Safety system testing with emergency stop and fault handling
- Process optimization and throughput analysis
- Predictive maintenance algorithm validation
Results: 90% reduction in commissioning time, 25% increase in production efficiency, 60% reduction in operator training time
Advanced Technology Stack
🖥️ Real-Time Simulation
- dSPACE SCALEXIO & MicroAutoBox
- National Instruments PXI
- Typhoon HIL
- MATLAB/Simulink Real-Time
- IPG CarMaker/TruckMaker
- Vector CANoe
⚡ Electrical Design
- Altium Designer
- KiCad Pro
- AutoCAD Electrical
- EPLAN Electric P8
- SIwave & PowerSI
- LTspice & PSpice
🎛️ Controls & Automation
- Siemens TIA Portal
- Rockwell FactoryTalk
- Schneider Unity Pro
- Wonderware InTouch
- LabVIEW & LabVIEW RT
- Beckhoff TwinCAT
📊 Data Acquisition
- National Instruments DAQ
- Keysight BenchVue
- Vector VN-Series
- DEWETRON OXYGEN
- HBK QuantumX
- Custom embedded solutions
🔬 Testing & Validation
- Vector vTESTstudio
- dSPACE AutomationDesk
- ETAS INCA
- IBM Rational DOORS
- PTC Integrity
- Jenkins CI/CD
⚙️ Dynamometer Systems
- Toyotech Rototest Dynamometers
- Horiba DYNAS3
- Kristl, Seibt & Co KS ADAC
- Froude Hofmann Sierra
- Custom AC/DC drive systems
- Regenerative test systems
Our Engineering Process
Systematic approach to delivering robust, validated engineering solutions
Requirements Analysis & System Architecture
Comprehensive requirements gathering, system specification development, and architecture design. We establish clear technical objectives, performance criteria, and validation strategies.
Design & Simulation Development
Detailed electrical and controls design with physics-based simulation model development. Includes schematic design, PCB layout, control algorithm development, and virtual validation.
Hardware Integration & Testbed Construction
Physical system integration, real-time hardware setup, and comprehensive testbed commissioning. Includes safety system integration and operational procedure development.
Testing & Validation
Comprehensive testing campaign execution with automated test procedures, data analysis, and performance validation against specifications. Includes boundary condition and fault injection testing.
Documentation & Training
Complete system documentation, user manuals, maintenance procedures, and operator training. Includes knowledge transfer and ongoing support planning.
Transform Your Engineering Challenges Into Solutions
Whether you need electrical design expertise, advanced testing capabilities, or complete system-level solutions, our engineering consulting team delivers results that matter.
🎯 Our Expertise
- Electrical & Controls Design
- HIL/VIL Testing Systems
- Data Acquisition Solutions
- System-Level Integration
🚀 Proven Results
- 65% reduction in testing time
- 80% faster validation cycles
- 40% cost savings achieved
- 99.9% system reliability
🔧 Industries Served
- Automotive & Transportation
- Industrial Automation
- Aerospace & Defense
- Research & Development
Ready to accelerate your engineering projects with proven expertise and cutting-edge solutions?
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Virtual Consultations
FREE Initial Consultation
Schedule your complimentary virtual meeting to discuss your needs
Email Us
[email protected]Call Us
(323) 9-PRYSM8Monday - Friday, 8AM - 6PM EST
Remote Support Nationwide
On-site service available in Greater Detroit Area