Shaping the Future of Mobility with Innovative Tailgate Testing Solutions Tata Motors, Limited

Format:

Book

Conference/Event

Author/Creator:

More, Shweta, author.

Contributor:

Ghanwat, Hemant

Jagdale, Nitin

Jape, Akshay

Kulkarni, Shraddha

Shetti, Suraj

Conference Name:

Symposium on International Automotive Technology (2026) (2026-01-28 : Pune, India)

Language:

English

Physical Description:

1 online resource cm

Place of Publication:

Warrendale, PA SAE International 2026

Summary:

As vehicles evolve toward increased automation and comfort, Power Operated Tailgate (POT) have become a common feature, especially in premium and mid-segment vehicles. These systems, although user-friendly on the surface, involve complex interactions between electronic control units (ECUs), sensors, actuators, and mechanical systems. Ensuring the reliability, safety, and robustness of these features under diverse operating conditions presents a significant validation challenge. Traditional testing methods, which rely heavily on physical prototypes and manual interaction, are often time-consuming, expensive, and prone to human error. Moreover, testing certain safety [3] features, such as anti-pinch or stall protection, under real physical conditions poses inherent risks and limitations.This paper presents a Hardware-in-Loop (HiL)[1] based testing approach for POT [2] systems, offering a safer, faster, and more comprehensive alternative to conventional validation methods. The HiL platform is built around a real-time test environment using Real Time Software, framework, integrated with MATLAB/Simulink [5] based plant models representing motor behaviour, hall sensors, and tailgate dynamics. The ECU under test communicates via CAN [4] and other physical I/Os, while the plant models simulate realistic vehicle responses in real time.The HiL approach enables full automation of functional, diagnostic, and safety validation of the tailgate system including open/close commands, fault injections (open circuit, short faults), latch and sensor logic, and anti-pinch scenarios. This methodology significantly reduces prototype dependence, accelerates ECU software validation, and increases overall test coverage. Results show substantial improvements in fault detection, regression testing efficiency.The proposed solution demonstrates how HiL [1] testing is not only a cost-effective validation method but also a strategic enabler for scalable and safe development of automotive mechatronic systems. This paper concludes by discussing the long-term benefits and future scope of enhancing the HiL setup with remote diagnostics, and seamless integration with other systems.The automotive industry is undergoing a transformation with a growing emphasis on comfort, convenience, and automation. Power Operated Tailgate (POT) have become an integral part of modern vehicles, offering hands-free access, anti-pinch

Notes:

Vendor supplied data

Publisher Number:

2026-26-0473

Access Restriction:

Restricted for use by site license