Revision 1.3 · Technical White Paper

EVO vHIL
Full-Stack Virtual Validation

A system-level framework for validating high-voltage EV powertrain software — before hardware exists.

84S
HV Traction Cells
4S
LV Auxiliary Pack
6
Architecture Layers
ISO 15118
CCS Fast Charge

What is EVO vHIL?

A virtual Hardware-in-the-Loop platform designed to simulate, validate, and stress-test high-voltage EV systems entirely in software.

EVO vHIL integrates production-intent embedded firmware with an Android Automotive OS control daemon, connected over a virtualized CAN network — all executing without a single physical component.

The result is a complete, closed-loop powertrain simulation where engineers can inject fault conditions, test thermal runaway responses, and validate DC Fast Charging sequences that would be physically dangerous or impossible on a real bench.

  • Production C/RTOS BMS firmware on simulated 32-bit MCU (Renode)
  • 🧠Native C++ VCU daemon executing within Android Automotive OS
  • 🔌SPI-based ISO 15118 CCS Type 2 fast-charging interface
  • 🔋Dual-pack topology: 84S HV traction + independent 4S LV auxiliary
  • 🛡️ISO 26262-inspired fail-safe safety model with atomic faulting
  • 🔬Deterministic fault injection pipeline for CI/CD integration
EMBEDDED POWERTRAIN BMS Firmware · C / RTOS 84S HV + 4S LV Pack MCU EMULATOR Renode 32-bit simulation CAN Frames MIDDLEWARE BRIDGE Python · Stream Parser → CAN Encoder → Socket Injector vCAN / UDP VCU SAFETY DAEMON Native C++ · AAOS Vendor Partition Safety Engine + VHAL Mapping SPI DRIVER Linux spidev ISO 15118 / PLC IPC / Broadcast PLC Signal DASHBOARD UI VHAL / Android UI Layer EVSE / CHARGER CCS Type 2 Station LIVE EVO vHIL · System Architecture · Rev 1.3
C / RTOS Android Automotive Python Bridge ISO 15118

⚡ The Core Design Principle

The control system must survive the failure of the traction system.

Dual-Pack Topology

Redundancy applied to consumer EV architecture — a dedicated 4S LV pack ensures control plane continuity through any traction failure.

⚠️
The DC-DC Problem
In conventional EVs, the 12V rail is derived from the traction pack. When the HV pack fails, the 12V rail collapses simultaneously — taking down the VCU, contactor coils, and safety sensors at the same instant. Uncontrolled. Unmonitored. Unlogged.
🔋
The EVO Solution
A physically independent 4S lithium pack powers the entire 12V rail. A total failure of the 84S HV pack leaves the VCU executing, contactor coils powered, and BMS in full control to sequence an ordered, logged, graceful shutdown.
🛡️
LV System Guarantees
The LV domain maintains sufficient energy for a full HV isolation sequence under any condition. LV degradation is detected and acted upon before contactor coils can no longer be held closed — always through defined, controlled states.
🏎️
Aerospace-Grade Redundancy
This architectural pattern is common in aerospace and motorsport applications. EVO applies it to consumer EV design — validated entirely in a virtual environment before any physical hardware is built.

Explore the System

Scope & Disclosure

This document describes the EVO architecture at a system and interface level. Certain subsystems — including LV energy management and CCS charging control — are intentionally documented using externally observable guarantees rather than internal implementation details. This approach preserves proprietary design elements while ensuring all safety-critical behaviors and system-level invariants are clearly defined.

Technical White Paper Revision 1.3 Pre-Production Architecture