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Faster Plant Models for SiL and Hill

Faster plant models for SiL and HiL

Modern motion-control applications such as active suspension, brake-by-wire, and integrated vehicle dynamics depend on accurate plant models for simulation and validation. The challenge is that conventional physics-based modeling is slow to build, hard to recalibrate for each test scenario, and often struggles to represent the nonlinear behavior engineers see in real measurements. That becomes a real bottleneck when teams want to frontload validation and run meaningful SiL and HiL testing earlier in development.

Key challenges

High manual modeling effort

Building and updating physics-based plant models takes significant time, requires deep domain expertise, and creates rework when requirements change.

Nonlinear behavior gap

Hand-built models often miss real system effects visible in measurement data.

Variant overhead

Different test targets need different model behavior, but manual recalibration does not scale.

Delayed frontloading

Missing real-time capable models slows SiL and HiL validation.

Engineer working on a laptop with ETAS software, featuring AI-driven analytics, machine learning, and workflow automation visualizations for automotive software development.

The ETAS toolchain combines ASCMO and INCA-FLOW into a data-driven workflow for building and calibrating plant models from measurement data. Instead of deriving the model from physical first principles, ASCMO learns system behavior directly from test drives or test bench data and generates behavioral models automatically with data-driven methods. This makes it possible to create accurate virtual representations of complex mechatronic systems faster and to cover different model variants as part of the same approach.

Once the model is available, INCA-FLOW automates the calibration workflow for specific target behaviors such as comfort, sport, or eco characteristics. Engineers can define repeatable workflows to adjust model parameters and generate calibrated variants for different test cases without rebuilding the model manually each time. The resulting models can then be exported in standard formats such as FMU (Functional Mock-up Unit) or as optimized C-code, so they can be used directly in SiL and HiL environments and reused wherever real-time capable plant models are needed.

Your benefits

Cut model creation time dramatically

Move from months of manual modeling effort to a workflow measured in days.

Improve simulation realism

Build models from real measurement data to capture nonlinear system behavior more accurately.

Frontload validation effectively

Give SiL and HiL teams usable plant models earlier and reduce reliance on physical prototypes and test benches.

Generate variants faster

Create calibrated model versions for different test scenarios with an automated, repeatable process.

Portrait Jeremie Balloy

With ASCMO and INCA-FLOW, engineers can turn measurement data into simulation-ready plant models much faster, calibrate variants with far less manual effort, and start meaningful virtual validation earlier in the development cycle.

Jeremie Balloy, Regional Solution Field Lead, ETAS Western Europe

ETAS solutions for measurement & calibration

Laptop with ETAS ASCMO software

ETAS ASCMO

Data-based modeling and model-based calibration

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INCA-FLOW

Guided calibration and test automation for ECUs

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INCA

Tools for measurement, ECU calibration, and diagnostics

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Measure data analyzer (MDA)

Unlock new insights in ECU development with innovative analysis solutions

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Knowledge base

Our Knowledge base is your central hub for practical guidance and expertise. It provides in-depth insights into automotive software and engineering, equipping you with the practical information you need to succeed.

Our local experts - strong service, always on your side

Dennis Roat

Portrait of Dennis Roat
Regional Solution Field Manager, North America

Dennis Roat

In my role as solutions Field Lead, I support hardware and software solutions across the Americas, with a focus on enabling development across all motion domains. As vehicle functions become increasingly interconnected, from propulsion to braking and steering, our close collaboration with customers provides insight into system-level challenges. We translate these learnings into targeted customizations and integrated toolchains that reduce complexity, streamline workflows, and shorten development cycles. This approach allows us to deliver meaningful, cross-domain value and strengthen long-term customer partnerships.

Wu Zheng

Portrait of Wu Zheng
Regional Solution Field Manager, China

Wu Zheng

As Regional Product Manager for INCA in China, I lead a team that covers customer projects in all vehicle motion domains, from powertrain to braking, suspension and steering. By tailoring integrated calibration, measurement and application solutions to Chinese customers and leveraging centralized E/E architectures and tool harmonization, we deepen motion‑centric workflows, accelerate development, and improve efficiency and quality as a trusted INCA partner across China.

Younduck Seo

Portrait of Youndock Seo
Regional Solution Field Manager, Korea

Younduck Seo

As a Regional Manager for Korea, I am committed to empowering our automotive customers by delivering specialized, on-the-ground support that is finely tuned to the unique demands of the Korean market.
My team excels at seamlessly integrating advanced measurement and calibration HW and SW solutions for the Vehicle Motion Control Systems,  enabling our customers to accelerate development timelines, boost vehicle performance, and solve complex issues with exceptional speed and accuracy. We function as your local link to a worldwide network of experts, providing customized solutions and strategic insights to propel your success in a competitive industry. Our goal is to be your trusted ally in shaping the future of vehicle motion.

Anuroopa Varsha

Portrait of Anuroopa Varsha
Regional Solution Field Manager, India

Anuroopa Varsha

As Regional Solution Field Manager, I focus on helping OEMs and Tier-1 suppliers reduce complexity, and accelerate development as vehicle architectures evolve toward centralized, software-defined platforms. At ETAS India, we combine >19 years of customer support and domain expertise with ETAS’s global leadership to enable seamless, cross-domain measurement and calibration across powertrain, chassis, and emerging motion controllers. Our integrated tool ecosystem provides end-to-end visibility and control across the vehicle dynamics domain, helping customers manage increasing system complexity.

Jeremie Balloy

Portrait of Jeremie Balloy
Regional Solution Field Lead, Western Europe

Jeremie Balloy

As Regional Solution Field Lead for Western Europe, I work closely with customers across multiple countries, staying connected to market trends, local challenges, and emerging opportunities across the motion domain. My goal is to be a trusted innovation partner, helping customers navigate technological change and accelerate development.

At ETAS, we collaborate with OEMs, suppliers, and key stakeholders to understand evolving customer needs and develop solutions for today’s business requirements and tomorrow’s mobility challenges. Using agile development methodologies, we rapidly transform ideas into tangible results.

Yoshio Watanabe

portrait Watanabe Yoshio
Regional Solution Field Manager, Japan

Yoshio Watanabe

Exceptional support that exceeds customer expectations and flexible problem-solving capabilities are the unshakeable strengths of ETAS Japan. We begin by deeply understanding the specific requirements, challenges and future vision of each individual customer. By promptly delivering optimal solutions and high-quality services, we are committed to reliably enhancing our customers' competitiveness.

Should you have any requests regarding the efficiency improvement, quality enhancement, or new technology adoption in application software development, please feel free to contact us at any time.