Keywords: hardware-in-the-loop, hot box detector, energy harvesting, wireless sensor node, energy management.

This research presents the development of an on-train self-powered hot box detector, utilizing a hardware-in-the-loop (HIL) testing method. Real-time energy harvesting system simulation enables thorough analysis and optimization prior to developing prototypes and conducting in-service tests. The integration of a vibration energy harvesting system, power storage and smart sensor node is described as well as the derivation of real-time models delivering an on-line estimation of the generated electrical power. During HIL tests with vibration records of an actual running gear, energy generation is balanced with consumption by data acquisition, signal processing and communication. Finally, the optimized prototype is developed and tested, first in the laboratory and then on an actual freight car

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