FPGA-Based Dual Learning Model for Wheel Speed Sensor Fault Detection in ABS Systems Using HIL Simulations

The rapid evolution of modern vehicles into intelligent and interconnected systems presents new complexities in both functional safety and cybersecurity. In this context, ensuring the reliability and integrity of critical sensor data, such as wheel speed inputs for anti-lock brake systems (ABS), is essential. Effective detection of wheel speed sensor faults not only improves functional safety, but also plays a vital role in keeping system resilience against potential cyber–physical threats. Although data-driven approaches have gained popularity for system development due to their ability to extract meaningful patterns from historical data, a major limitation is the lack of diverse and representative faulty datasets. This study proposes a novel dual learning model, based on Temporal Convolutional Networks (TCN), designed to accurately distinguish between normal and faulty wheel speed sensor behavior within a hardware-in-the-loop (HIL) simulation platform implemented on an FPGA. To address dataset limitations, a TruckSim–MATLAB/Simulink co-simulation environment is used to generate realistic datasets under normal operation and eight representative fault scenarios, yielding up to 5000 labeled sequences (balanced between normal and faulty behaviors) at a sampling rate of 60 Hz. Two TCN models are trained independently to learn normal and faulty dynamics, and fault decisions are made by comparing the reconstruction errors (MSE and MAE) of both models, thus avoiding manually tuned thresholds. On a test set of 1000 sequences (500 normal and 500 faulty) from the 5000 sample configuration, the proposed dual TCN framework achieves a detection accuracy of 97.8%, a precision of 96.5%, a recall of 98.2%, and an F1-score of 97.3%, outperforming a single TCN baseline, which achieves 91.4% accuracy and an 88.9% F1-score. The complete dual TCN architecture is implemented on a Xilinx ZCU102 FPGA evaluation kit (AMD, Santa Clara, CA, USA), while supporting real-time inference in the HIL loop. These results demonstrate that the proposed approach provides accurate, low-latency fault detection suitable for safety-critical ABS applications and contributes to improving both functional safety and cyber-resilience of braking systems.

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