Scalable HILS Validation for Forklift OEM

Background

With a growing portfolio of electric and autonomous forklifts, a Japanese Forklift manufacturer needed a scalable and efficient validation framework for testing its Forklift Main Controller ECUs. Leveraging Hardware-in-the-Loop Simulation (HILS), Tata Elxsi helped establish and expand a robust test infrastructure across multiple forklift variants and controllers, accelerating development while enhancing safety, reliability, and product quality.

Challenge

The OEM faced multiple challenges in scaling their validation ecosystem:

• Variant Complexity: Existing HILS setups were limited to the current model, while new forklift variants required unique validation environments.
• System Requirements: Restructuring and prioritization were carried out across twelve functional groups to ensure complete coverage.
• Test Coverage: Development and prove-out of Priority test cases, including wire-cut scenarios, demanded automation and precision.
• Framework Scalability: The HIL framework had to support multiple variants without redundant test cases.
• Integration Needs: Mechanical, electrical, and embedded systems engineering had to align seamlessly with evolving specifications.

Solution

Tata Elxsi delivered a comprehensive validation and automation program:

• Enhanced HILS setups for the current forklift main controller.
  Implemented specification changes and developed new HILS setups for the forklift variants.
• Expanded HILS infrastructure to support validation of various controllers.
• Restructured system requirements across twelve Functional Groups.
• Developed master functional test cases, diagnostic scenarios, and automated execution across all variants.
• Improved the HIL framework with enhanced libraries, compound commands, and multi-variant handling.
• Automated model updates and enhanced CANopen models for seamless integration.
• Delivered end-to-end engineering support covering embedded validation, test automation, mechanical/electrical engineering, design evolution, and product customization.
• Automated Test Suite supports automated test execution, test scheduling, test result overview, and continuous integration with repeatable validation cycles

Impact

The engagement delivered significant outcomes:

• Full Lifecycle Ownership: spanning design, validation, and scale — with AI‑driven test case generation powered by the GENE framework.
• Faster Development: Automation and reuse accelerated timelines.
• Improved Productivity: Standardization reduced effort and increased predictability.
• Strategic Value: Reduced delivery risk, faster onboarding of new forklift variants, and platform readiness for future product lines.

Where We Are Now

The engagement, initiated in 2025, is ongoing and has established Tata Elxsi as a long-term scalable engineering partner. Current focus areas include:

• Continuous expansion of HILS for new forklift models.
• Advanced automation of test execution across all priorities.
• Strengthening global delivery through onsite + offshore collaboration.
• Building platform readiness for next-generation forklift controllers.

Services Rendered

• Requirements Management
• HIL Validation
• Test Framework Engineering
• Functional Testing
• Diagnostic Testing
• AI-Based Test Generation
• Test Automation
• Reporting & Analytics