Resh Technical Solutions

08/01/2026

Collecting data is easy. Turning that data into an engineering decision is where the real work begins.

In the latest video in my All About HIL Testing series, I cover one of the areas where HIL testing really starts to generate value: Data Collection, Monitoring, and Debugging

A HIL bench can generate thousands of signals, millions of samples, network traffic, controller states, fault messages, and hours of telemetry.

But more data does not automatically mean better validation.

The real questions are:

What is the system actually telling us?

What happened first?

What caused the response we are seeing?

Is the behavior repeatable?

And most importantly, what engineering decision should we make based on the evidence?

In this Video, I walk through:

🔹 Real-time monitoring and telemetry

🔹 Data logging and recording

🔹 Why time synchronization matters

🔹 Reading and interpreting waveforms

🔹 Root-cause investigation

🔹 Practical debugging strategies

🔹 Turning test results into engineering decisions

One lesson I have learned throughout my career is that good debugging is rarely about guessing the answer faster.

It is about reducing uncertainty systematically. Reproduce the problem. Simplify the system. Compare expected behavior to actual behavior.

Follow the evidence. And change one thing at a time.

That discipline is what turns a mountain of test data into useful engineering knowledge. At the end of the day, successful validation is not measured by how much data we collect.

It is measured by how much we learn from it and what we do with that knowledge.

🎥 Watch All About HIL Testing Part 7: Data Collection, Monitoring, and Debugging here:

https://youtu.be/ghc9IxezR4c

Next up, I’ll bring everything together with a real-world HIL validation example that follows a system from startup through fault injection, troubleshooting, analysis, and successful verification.

07/25/2026

You can have a million-dollar HIL bench and still have a poor validation program. Why? Because the value of a HIL system isn't determined by how sophisticated the hardware is. It's determined by the quality of the tests you run on it.

In the latest video in my All About HIL Testing series, I get into one of the most important questions in Hardware-in-the-Loop testing:

• What should we actually test?

• Good testing doesn't happen by accident.

• Every test should have a clear engineering purpose.

• What requirement are we verifying?

• What behavior are we trying to understand?

• What happens at the boundaries of operation?

• How does the controller respond when something fails?

• And most importantly, how do we objectively determine whether the test passed or failed?

In Part 6: Designing Effective HIL Tests, I cover:

• Starting with requirements and establishing test traceability

• Functional verification and controller state validation

• Boundary and stress testing to understand system margins

• Fault injection and failure simulation

• Test automation and regression testing

• Defining objective pass/fail criteria

• Building realistic HIL validation scenarios

Here is the YT Link: https://youtu.be/UYZPibbiicw

One of the points I really want engineers to take away from this chapter is that running tests and performing validation are not necessarily the same thing.

You can execute hundreds of tests and generate mountains of data.

But if those tests aren't tied back to requirements, risks, expected behavior, and objective acceptance criteria, you may still struggle to answer the question that actually matters: Did we prove the system performs the way it is supposed to?

That's where thoughtful test design makes the difference.

The purpose of testing isn't simply to generate data. The purpose of testing is to generate engineering knowledge that allows us to make better decisions.

If you work in HIL, systems engineering, controls, verification and validation, or test engineering, I'd be interested to hear your perspective:

What's one HIL test scenario that uncovered a problem you never expected to find?

Developing HIL Test Cases and Validation Scenarios | Chapter 6 – De...

07/18/2026

My latest video just dropped on !

One of the biggest misconceptions about Hardware-in-the-Loop (HIL) testing is that success starts when you press Run.

It doesn't.

Successful HIL testing begins long before the first simulation executes. It starts with planning the bench architecture, designing reliable wiring, properly installing the Device Under Test (DUT), verifying configurations, following disciplined startup procedures, and ensuring the entire system is safe and ready for testing.

In Part 5 of my "All About HIL Testing" series, I walk through the engineering practices that separate a dependable HIL laboratory from one that constantly struggles with unreliable data and unnecessary troubleshooting.

In this video, I cover:

✔ Planning a scalable HIL bench architecture

✔ Wiring and signal management best practices

✔ Proper DUT installation and configuration

✔ Controlled power-up and initialization

✔ Calibration and bench checkout

✔ The role of the HIL operator

✔ Pre-test safety verification

✔ Long-term best practices for maintaining a world-class test environment

Check it out on YouTube: https://youtu.be/KDWjAwjL3O0

Throughout my career, I've learned that great validation organizations aren't defined by the equipment they own—they're defined by the discipline of the engineers who operate it.

Reliable laboratories produce reliable data.

Reliable data leads to better engineering decisions.

And better engineering decisions build better products.

If you're involved in aerospace, automotive, industrial controls, robotics, medical devices, or any system that relies on real-time controls, I think you'll find something valuable in this chapter.

I'd love to hear how your team approaches HIL bench setup and operation. What best practices have made the biggest difference in your organization?

Need help with your Reliability, Test, and Validation Projects? Feel free to contact me at www.tomresh.com to find out how I can help!

All About HIL Testing | Chapter 5 – Setup, Configuration, and Safe ...

07/11/2026

I just released Part 4 of my All About HIL Testing series: Closed-Loop Operation and Signal Flow.

I've found that one of the hardest concepts for people new to Hardware-in-the-Loop (HIL) testing isn't understanding the individual pieces—it's understanding how they all work together.

A HIL bench isn't just a simulator connected to a controller. It's a continuous feedback loop where the simulator, I/O, controller, and software are all interacting in real time. Every decision the controller makes affects the simulation, and every change in the simulation creates new inputs for the controller.

In this video, I walk through that entire process step by step:

How the real-time simulator generates the virtual environment
How sensor signals are emulated
How the controller processes those inputs using its actual production software
How actuator commands are fed back into the simulation
Why deterministic timing is critical to getting meaningful test results

I also use a simple cooling fan example to show how a closed-loop HIL system behaves, because sometimes a practical example makes the concepts much easier to understand than diagrams alone.

Whether you're just getting started with HIL or you've been working with these systems for years, I hope this video helps make the closed-loop process a little easier to visualize.

If you've ever built, operated, or debugged a HIL bench, I'd be interested to hear what you think is the most challenging part of getting a system running reliably.

You can watch the latest video here:
🎥 https://youtu.be/WLI-lkgsrlI

If you find it helpful, I'd appreciate it if you shared it with others who are interested in controls, simulation, and system validation.

07/04/2026

Have you ever looked at a Hardware-in-the-Loop (HIL) test bench and wondered what all those racks, controllers, computers, and cables actually do?
At first glance, it can look incredibly complex. But once you understand the architecture, everything starts to make sense.
In my newest video, Chapter 3 – Understanding the HIL Bench, I take you inside a typical HIL system and explain the purpose of each major component, including:
• Real-time simulators
• Device Under Test (DUT)
• I/O systems
• Signal conditioning and DAQ
• Power systems
• Communication networks
• Operator interfaces
• Safety systems
Whether you're new to HIL testing or have been working with these systems for years, understanding how the pieces fit together is fundamental to building, operating, and troubleshooting a successful HIL bench.
My goal with this series is to make complex engineering topics easier to understand and help more engineers develop a strong foundation in Hardware-in-the-Loop testing.

If you've ever walked into a Hardware-in-the-Loop (HIL) lab and won...

06/27/2026

Why do the world's leading engineering companies invest so heavily in Hardware-in-the-Loop (HIL) testing?
It isn't because HIL is the latest technology.
It's because it helps engineering teams find problems when they're still inexpensive to fix.

After spending years leading test and validation organizations across aerospace and electric vehicles, I've seen the same pattern over and over.

A software bug found during development might take a few hours to resolve.

That same bug discovered during system integration can impact multiple engineering teams, delay schedules, require hardware changes, and trigger weeks of additional testing.
If it reaches the customer, the cost grows even further.

That's why HIL has become a standard development tool across industries like:

✈️ Aerospace
🚗 Automotive & Electric Vehicles
🤖 Robotics
🏭 Industrial Automation
🚀 Space Systems

In Chapter 2 of my All About HIL Testing series, I explain why organizations continue investing in HIL and the business value it provides.

We cover topics including:
✅ Finding defects earlier in development
✅ Reducing integration risk
✅ Improving safety during testing
✅ Fault injection and failure validation
✅ Repeatable testing for faster root-cause analysis
✅ Why HIL is as much a business strategy as it is an engineering tool

One of the biggest takeaways from this chapter is simple:
HIL doesn't eliminate engineering problems—it changes when you find them.

Finding a problem earlier almost always means it's faster, cheaper, and easier to solve.

That's the real value.

If you're an engineer, engineering leader, systems engineer, software developer, or anyone involved in product development, I hope you'll find this video valuable.

I'd also love to hear from the community:

What's the biggest integration issue you've seen that could have been caught earlier with better validation?

🎥 Watch the video here: https://youtu.be/dqd9ZqAz-DY?si=iRLD8Tx86g47-HT-

Chapter 2 – The Business and Engineering Value of Hardware-in-the-L...

06/22/2026

Changing the world is not for the faint of heart!

06/20/2026

https://youtu.be/bgyN7FMZvro?si=IYNzCxjEn5YoZgFX

06/20/2026

🚀 New Video Released: All About Hardware-in-the-Loop (HIL) Testing Part 1

How do engineers test and validate complex systems before a vehicle, aircraft, robot, or industrial machine is ever built?

The answer is Hardware-in-the-Loop (HIL) testing.

In Part 1 of this new series, I explain the fundamentals of HIL testing, how it works, and why it has become one of the most valuable tools for developing and validating today's complex systems.

HIL testing allows engineers to find problems earlier, reduce risk, improve safety, and gain confidence before expensive prototypes or production hardware are put at risk.

Whether you work in automotive, aerospace, robotics, industrial automation, or energy systems, understanding HIL testing is becoming increasingly important.

If you're new to HIL or want a better understanding of how engineers validate hardware and software together, this video is a great place to start.

I hope you enjoy it.

In this video, you'll learn:

✅ What is Hardware-in-the-Loop (HIL) testing

✅ How real hardware interacts with real-time simulation

✅ What a Device Under Test (DUT) is

✅ How closed-loop testing works

✅ Why traditional testing methods create challenges

✅ Real-world examples from automotive, aerospace, and industrial systems

✅ How HIL testing reduces risk, lowers cost, and accelerates development

Whether you're a test engineer, controls engineer, systems engineer, validation engineer, engineering student, or simply interested in modern product development, this video provides a practical introduction to the world of HIL testing.

One of my favorite definitions from the video:

"HIL testing allows engineers to test before reality catches up."

🎥 Watch the video here: https://youtu.be/bgyN7FMZvro?si=IYNzCxjEn5YoZgFX

I'd love to hear from others who have worked with HIL systems.

What HIL platforms have you used? dSPACE, NI VeriStand, Speedgoat, OPAL-RT, Typhoon HIL, or something else?



https://youtu.be/bgyN7FMZvro?si=IYNzCxjEn5YoZgFX

🚀 What is Hardware-in-the-Loop (HIL) Testing? | Understanding the H...

08/10/2025

Struggling to set reliability and confidence targets and then back them up with real test data? 🎯

I just released a clear, practical walkthrough for working engineers. In this video, I show how to choose the right reliability and confidence levels, translate mission requirements into test requirements, and calculate sample sizes using the parametric binomial reliability demonstration method.

What you’ll learn

Reliability vs. confidence in plain language

How to set targets from customer needs, safety risk, cost of failure, and competitive benchmarks

Converting mission reliability to a test target, including time scaling with a Weibull shape parameter

Parametric binomial basics for zero failures and for allowing failures

Step-by-step sample size calculations and how test time changes the math

Tradeoffs among sample count, test duration, and acceleration factor

Common mistakes to avoid when claiming a pass at a given confidence level

Who this is for

Reliability, design, validation, and quality engineers; test leads; and hardware managers who need defensible results for gate reviews and customer discussions.

Free resources + contact

Grab my reliability checklists and sample size quick sheet at the link in the video description. Need expert help with your validation plan or a second set of eyes on your numbers? Reach out: www.tomresh.com

Watch the video → https://youtu.be/30VlCqpMdHI

If it helps, give it a like, subscribe for more real-world reliability content, and drop a comment with the target and confidence you’re trying to demonstrate. 📊

Resh Tech is a leading engineering consulting firm specializing in vibration and shock testing, battery validation, reliability engineering, and product durability testing for industries including automotive, aerospace, military, and EV battery safety. Our expert services include DFMEA development,....