Hardware-in-the-Loop Testing of Vehicle’s Electronic Stability Control System

: Conducting laboratory and field testing is a classic approach to the development and certification of vehicles and their automotive components. These processes are costly and time-consuming. The serial installation of mechatronic systems in the car forced software and electronic systems engineers to master a new approach to testing and development - "physical" simulation (Hardware-in-the-loop). The aim of the research in this article is to develop, implement and validate a “physical” simulation method for evaluating the performance of Electronic Stability Control (ESC) systems. In this research, an ESC HIL-testbench, a mathematical model of the vehicle curvilinear movement in Adams Car, and a method for converting it into a Simulink-model, that allows generating a C-code, were developed and implemented. To assess the adequacy and correctness of the “physical” simulation, full -scale dynamic manoeuvres were carried out on the object of research - the Gazelle Next vehicle with ESC-system “ Bosch ESP 9.1 ” . In this article, the results of road tests and simulations, as well as an assessment of their convergence, are presented in tabular and graphical forms. The maximum discrepancy was 19% with the maximum allowable one up to 25% in accordance with the standard ISO 19635.