Hardware-in-the-Loop Robots for Real-Time Structural Testing
Automated Structural Tech delivers cyber-physical HIL robotic systems for responsive, real-time simulation of structural behavior.
Overview
Hardware-in-the-Loop (HIL) Testing Robots revolutionize how structural systems are tested by combining real-time digital simulations with physical components under stress. These robotic systems act as the bridge between virtual models and real-world structural behavior, allowing engineers to replicate, observe, and adjust system responses under dynamic load conditions—before full-scale deployment. HIL testing robotics are especially critical in validating control systems, seismic response mechanisms, fatigue resistance, and adaptive structures across infrastructure, civil, and industrial engineering applications. By simulating complex real-time scenarios—such as earthquakes, wind loads, or live traffic—they enable faster and more reliable structural innovations. Automated Structural Tech, a trusted B2B company based in Vancouver, BC, provides state-of-the-art HIL robotic solutions to clients across North America. Our offerings blend technical excellence, product reliability, and deep industry knowledge to support engineers and infrastructure specialists with cutting-edge, scalable systems.
Core Components of Hardware-in-the-Loop (HIL) Testing Robots
In addition to offering products and systems developed by our team and trusted partners for Hardware-in-the-Loop (HIL) Testing Robots, we are proud to carry top-tier technologies from Global Advanced Operations Tek Inc. (GAO Tek Inc.) and Global Advanced Operations RFID Inc. (GAO RFID Inc.). These reliable, high-quality products and systems enhance our ability to deliver comprehensive technologies, integrations, and services you can trust. Where relevant, we have provided direct links to select products and systems from GAO Tek Inc. and GAO RFID Inc.
- Real-time robotic actuators – Use Zigbee End Devices for real-time robotic response synchronization in structural integrity evaluations of insured properties.
- Feedback sensors – Deploy Motion & Position Sensors to continuously monitor strain and displacement during infrastructure testing tied to policy compliance.
- High-speed controllers – Implement Wi-Fi HaLow Gateways/Routers for microsecond-level feedback loops in dynamic simulation systems used by insurers.
- DAQ modules – Device Edge platforms support compact DAQ deployment for capturing high-resolution data in insurance asset evaluations.
- Structural specimens or mockups – NFC & HF RFID Readers, Tags & Accessories tag mockups for condition validation and compliance reporting in claim simulations.
- Real-time simulation environments (e.g., MATLAB/Simulink, LabVIEW RT): Model the virtual structure, environmental stimuli, and mechanical control loops.
- Robotic control software: Orchestrates synchronization between simulation and physical action.
- Safety and override modules: Prevent overloads or system failure during high-stress test phases.
- Analysis and visualization tools: Present comparative data between predicted and observed behavior.
- Edge-to-cloud data logging platforms: For long-term performance tracking and compliance reporting.
- Remote access modules: Allow offsite experts to monitor and adjust test routines in real time.
- Integration-ready APIs: Enable connectivity with structural BIM platforms or digital twin systems.
Key Features and Functionalities
- Real-time bidirectional control between simulation and hardware
- Customizable test parameters for multiple structural scenarios
- Safety interlocks and emergency shutdown capabilities
- Adaptive feedback response based on physical measurements
- Scalable from component-level to system-level tests
- Interfaces with popular modeling software and mechanical controllers
Integrations and Compatibility
- Compatible with Simulink Real-Time™, LabVIEW, and custom simulation engines
- Interfaces with GAO Tek DAQs, force sensors, and structural controllers
- Compatible with structural load frames, shake tables, and custom rigs
- API integration with Digital Twin platforms and IoT-enabled edge sensors
- PLC and SCADA system compatibility for industrial automation needs
Benefits of Our HIL Testing Solutions
- Accelerated prototyping of structural systems without risking full-scale damage
- Reduced cost by minimizing reliance on destructive physical testing
- Higher confidence in safety-critical designs and control strategies
- Greater flexibility to simulate earthquakes, dynamic loads, or extreme events
- Improved data quality through synchronized digital-physical measurements
Applications
Earthquake-resistant building and bridge design
Aerospace structural simulations under variable load
Infrastructure resilience testing under flood, fire, or impact stress
Offshore structure validation in wind and wave conditions
Research laboratories for academic and industrial innovation
Industries We Serve
Civil and Structural Engineering
Aerospace & Defense
Construction & Infrastructure Development
Energy & Utilities
Transportation & Rail Systems
Research and Academia
Relevant U.S. & Canadian Standards & Regulations
- ASTM E2126
- IEEE 1558
- AASHTO LRFD Bridge Design Specifications
- CSA S6: Canadian Highway Bridge Design Code
Case Studies
Case Study 1 – U.S. (California)
A California-based earthquake simulation lab integrated Automated Structural Tech’s HIL robotic testing arms with a real-time seismic simulation engine. The system enabled testing of new damping systems for skyscrapers before deployment in earthquake-prone zones. Test routines simulated 8.0 magnitude quakes, offering 30% faster certification and enhanced safety profiles.
Case Study 2 – U.S. (New York)
An East Coast transit authority used HIL platforms to validate fatigue behavior in subway tunnel reinforcements. By simulating dynamic train loads and environmental factors, the platform revealed hidden stress concentrations, enabling preventive reinforcement and saving over $1.2M in potential repairs.
Case Study 3 – Canada (Ontario)
A major engineering school in Ontario employed our HIL robotic systems for bridge girder testing in a smart infrastructure research program. Integrated with GAO RFID load cells and DAQs, the system helped evaluate next-gen fiber-reinforced concrete under cyclic traffic loads, leading to a new design standard for rural highway bridges.
Looking to enhance your infrastructure monitoring
capabilities with automated crack detection?
Our team at Automated Structural Tech is here to help you select the right system, integrate it seamlessly into your workflows,
and ensure long-term reliability. Let’s discuss your project today! Visit our Contact Us page to request more information, product
demos, or a custom consultation.