Traditional design and development methods utilize analytical and physical prototypes to improve understanding of a system or product. Hardware-in-the-loop simulation (HILS), a technique that is increasingly applied in the field of control system development, combines analytical and physical prototyping. This paper discusses the application of HILS with scaled physical hardware as a means of increasing the efficiency of the design and development process. A case-study example using a scaled prototype vehicle with components of the drivetrain represented in software is presented. The work concludes that the approach is feasible and could be applied in a number of areas, reducing development time and cost, but that care must be taken in its application to ensure that the process of scaling does not negate the key phenomena for which the physical component is introduced
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