High-Voltage Hardware-in-the-Loop (HIL) Testing System for 6KV CHB Simulation

Customer: World-Renowned Industrial Equipment Company

Project: High-Voltage Hardware-in-the-Loop (HIL) Testing System for 6KV CHB Simulation

Product Description

Syntronic collaborated with a global industrial equipment leader to design and deliver an advanced Hardware-in-the-Loop (HIL) testing system for validating complex high-voltage industrial equipment. The solution was engineered to simulate 6KV Cascaded H-Bridge (CHB) conditions with exceptional accuracy, enabling real-world performance testing in a controlled and safe environment.

By integrating custom hardware components including PLCs, controllers, acquisition units, switches, and interface boards into a unified system, Syntronic provided a complete testing platform that enhanced product validation accuracy, improved safety, and reduced testing cycles.

Scope

As a turnkey development partner, Syntronic took full responsibility for the concept, design, integration, and deployment of two complete HIL testing systems. The engagement encompassed high-voltage hardware design, real-time control systems, precision signal acquisition, and safety mechanism implementation.

Syntronic engineers designed specialized PLC controllers and acquisition units optimized for 6KV CHB simulation, ensuring exceptional accuracy and stable performance during high-voltage testing. Custom interface boards and switches were developed with advanced isolation and signal conditioning to maintain integrity under extreme operating conditions.

Robust firmware and software interfaces were integrated to provide engineers with real-time control and data acquisition tools, streamlining equipment validation and performance analysis. Syntronic also implemented comprehensive safety systems to protect operators and equipment during testing, maintaining full compliance with industrial safety standards.

Results

The collaboration resulted in the successful deployment of two fully functional HIL testing systems with advanced 6KV CHB simulation capabilities. The new systems improved validation accuracy by 35% and reduced overall testing time by 40%, allowing the customer to accelerate product development and bring new industrial equipment to market faster.

By implementing precise simulation and high-voltage control, Syntronic’s solution enhanced product reliability, reduced warranty risks, and established new benchmarks for testing efficiency in the industrial sector.

Key outcomes included:

• 35% improvement in validation accuracy for high-voltage equipment testing
• 40% reduction in testing time, accelerating time-to-market
• Enhanced reliability and quality assurance through comprehensive simulation
• Scalable testing infrastructure ready for future system upgrades and expansions

Through its integrated engineering expertise and turnkey development capabilities, Syntronic empowered the customer to achieve superior product validation, strengthen operational safety, and maintain their leadership in the industrial equipment market.