In today’s fast-paced world of electrification, motor control development is no longer limited to low-level coding and manual testing. Model-Based Design (MBD) has emerged as a game-changing methodology, enabling rapid prototyping, simulation, control validation, and automatic code generation. Various software tools now cater to different aspects of motor control development, from algorithm design to hardware-in-the-loop (HIL) testing. This article provides an overview of leading tools in this space.

Overview of Tools

1. MATLAB and Simulink (MathWorks)

The gold standard in model-based design. With dedicated toolboxes for motors, drives, and embedded targets, Simulink supports full-cycle development from modeling to code generation and HIL testing. It supports a wide range of processors, including TI C2000, STM32, and NXP platforms.

2. PLECS (Plexim)

Tailored for power electronics and motor drive systems, PLECS offers electrical, thermal, and mechanical co-simulation with real-time capabilities using the RT Box. Code can be generated for TI C2000, STM32, and ARM Cortex-M processors.

3. Altair Embed (formerly VisSim)

A strong visual tool for embedded motor control. With block diagram modeling and real-time code generation, it directly targets TI C2000, STM32, and ARM Cortex-M. Ideal for rapid prototyping of sensorless motor control algorithms.

4. dSPACE

Well-known for its real-time simulation and HIL platforms. dSPACE integrates tightly with Simulink and supports deployment on embedded processors such as TI C2000 and ARM Cortex-M, making it ideal for industrial and automotive control systems.

5. Dymola

A Modelica-based tool well-suited for multi-domain simulation. It supports exporting control logic to external platforms, such as Simulink, for code generation, enabling compatibility with embedded targets.

6. LMS Imagine.Lab AMESim (Siemens)

Excels in multi-physics system simulation. Though not a direct code generation platform, it integrates well with Simulink for controller design and embedded deployment.

7. MapleSim

Combines symbolic math and modeling for high-fidelity simulation. It supports code export for TI C2000 and ARM Cortex processors via connectors, allowing for complex system analysis with reduced equations.

8. Altair Activate

Blends Modelica and block-diagram modeling. While direct code generation is not a core feature, it supports the simulation of control strategies and system dynamics across various domains.

9. EICASLAB

Focused on control design and rapid prototyping, particularly in aerospace and automotive sectors. Generates embedded code, but with limited public info on supported microcontrollers.

10. DSHplus

Targeted at fluid power and mechatronics applications. While it excels at simulating actuator and hydraulic subsystems, its code generation and processor support are limited.

11. SimulationX (ESI/Ansys)

A powerful multi-domain simulator supporting mechanical, electrical, and control modeling. It works well with Simulink for code generation, though it doesn’t offer built-in support for embedded code.

12. Synopsys SaberRD

Popular in the automotive space for power electronics and mixed-signal system design. It supports simulation and fault analysis but relies on third-party tools for embedded code deployment.

13. Modelica / OpenModelica

Modelica is the modeling language behind tools like Dymola and OpenModelica. It offers open-source multi-domain modeling but relies on integration with Simulink or other tools for embedded deployment.

14. NI LabVIEW + VeriStand

Primarily used for real-time testing and system integration. Ideal for HIL setups with NI hardware like CompactRIO and PXI systems, but limited in motor modeling libraries.

15. TwinCAT 3 (Beckhoff)

Blends motion control, PLC, and CNC in one environment. Integrates with Simulink and supports x86 targets, making it suitable for industrial automation.

16. JMAG-RT

Specializing in electromagnetic simulation. While not a standalone MBD tool, it generates reduced-order models of electric machines for use in Simulink or PLECS.

17. Typhoon HIL

The industry leader in ultra-fast real-time simulation for power electronics and drive systems. While it doesn’t generate code, it plays a critical role in validation and compliance testing.

18. Scilab/Xcos

An open-source alternative for simulation and control logic prototyping. While it offers C-code generation, it lacks advanced features and motor libraries found in commercial tools.

Comparison Table of Model-Based Design Tools

Conclusion

Choosing the right model-based design tool depends on your target application, processor, and development goals. Tools like MATLAB/Simulink, PLECS, and Altair Embed lead in embedded code generation and real-time motor control. Meanwhile, tools such as Typhoon HIL, dSPACE, and JMAG-RT provide unparalleled support for validation and system-level integration.

Whether you’re prototyping an e-bike drive, developing an industrial servo system, or simulating an electric vehicle (EV) powertrain, leveraging the right tool can drastically reduce time-to-market and improve design confidence.