More and more electronic control units (ECU) are being integrated in the rapidly evolving automotive industry. In order to simplify and shorten the testing of ECU algorithms, hardware-in-the-loop (HIL) testing is becoming increasingly popular in the industry. For several applications common CPU based high level simulation software is not able to achieve a suitable temporal resolution in real-time. This paper presents an easy to use model representation with an integrated automatic solver selection. Therefore it is possible to simulate models with ideal solver and step size. The selection algorithm uses an automatic parameter-dependent model and run time analysis and can also be applied to non-linear differential algebraic equation systems with switching conditions by local linearization of the complete state space. In an existing automotive HIL-simulation the presented procedure was proven to allow an easy implementation of multi-state, nonlinear, non-continuous, ordinary differential algebraic equation systems. With the implementation in C++ a step size of up to 5 microseconds von a low power compact computer could be achieved.

Efficient, light-weight and compact electrical machines have been in particularly high demand since the rise of electromobility. One emerging machine concept is the permanent magnet excited axial-flux synchronous machine with a Yokeless And Segmented Armature Topology. In the context of an electric racing car of the Formula Student competition a flexible and closed toolchain was developed, allowing the design and dimensioning of the above-mentioned machine type in a power range of 10-100 kW, based on the desired power and rotational speed. The toolchain consists of an electromagnetic predesign and subsequent simulation in MATLAB/SIMULINK as well as the generation of a CAD model and manufacturing data in AUTODESK INVENTOR. An axial-flux machine designed for the Hamburg University of Technology racing car with a power of 30 kW and a rotational speed of 12 000 min(exp -1) achieves a power density of 6 kW kg(exp -1) at a diameter of 134 mm and a length of 131 mm.