01
Open circuit
The connection disappears completely.
∞ Ω · openALL CHANNEL TYPES
The FSB opens the line. It recreates a broken wire, unplugged terminal or completely lost connection.
Introducing FSB 2.0
Real faults. Real vehicles.
Full control.
A plug-and-play fault injection platform for technical training and vehicle development.
Connect to an ECU, BCM, BMS or almost any other electronic control module. Select a fault in Failure Simulation Studio and immediately observe how the real vehicle responds—without cutting wires or manually bugging the vehicle.
Request a launch consultation Discover how it works9
Fault functions
280
Physical through-channels
10
Simultaneous faults
0
Permanent vehicle modifications
Plug and play fault injection
No more manually bugging vehicles
Turn a suitable standard vehicle into a repeatable diagnostic training platform.
Traditional training requires someone to interrupt wires, alter connectors, add resistors or install hidden switches. Preparation takes time, restoring the vehicle takes more time and every modification introduces risk.
With FSB 2.0, connect the module-specific adapter cable, load its mapped profile and start the diagnostic exercise in Failure Simulation Studio.
Plug and play
Connect the module and load its profile.
Connect the module and load its profile.
No permanent changes
No cutting, splicing or hidden switches.
No cutting, splicing or hidden switches.
Ready to repeat
Clear and reload the same case.
Clear and reload the same case.
From a broken wire to a distorted PWM signal
FSB 2.0 recreates the electrical faults technicians meet in real vehicles. Start with a fault anyone can recognise, then progress to sensor, communication and actuator behaviour.
Fault function
Schematic
Signal / bus / power → what the box does
What it looks like in reality
02
Resistance & poor contact
The circuit still works—but not properly.
10 Ω–100 kΩSIGNAL
The FSB adds a selected resistance in series. This mimics corroded pins, loose terminals and damaged conductors.
03
Power voltage drop / poor ground
Voltage looks normal—until the circuit is loaded.
0.05–10 ΩPOWER / GROUND
The FSB adds low resistance to a power or ground path. The result is a realistic voltage drop under load.
04
Controlled short to ground
A damaged wire touches vehicle ground.
Protected · current-limitedPOWER / POWER SIGNAL
The FSB creates a protected path to vehicle ground. It reproduces damaged insulation without making an uncontrolled hard short.
05
Leakage / pull-up / pull-down
A small unwanted current biases the signal.
1 kΩ–1 MΩSIGNAL
The FSB connects the line through a selected resistance to ground or a validated reference. This recreates moisture, contamination and insulation leakage.
06
Sensor manipulation
The value is believable—but wrong.
Controlled attenuationSIGNAL
The FSB attenuates or shifts the sensor signal. The ECU receives a realistic but incorrect temperature, pressure or position value.
07
CAN & BUS faults
Communication becomes unstable or disappears.
60 Ω–10 kΩCAN / BUS
The FSB changes termination, loading or line resistance. Engineers can study communication errors on a validated bus pair.
08
Intermittent faults
The problem comes and goes.
Timed · patterned · randomTIME CONTROL
The FSB activates another fault for a chosen duration or pattern. This recreates heat-, vibration- and movement-related problems.
09
PWM signal injection
Actuator control can be reproduced and disturbed.
PWM · duty-cycle controlSIGNAL / ACTUATOR
The FSB injects or alters a PWM control signal. This enables realistic actuator, valve, motor and duty-cycle diagnostic cases.
One fault becomes an unlimited number of diagnostic cases.Run it continuously, activate it after a delay or make it intermittent—then combine faults across multiple channels for a complete vehicle scenario.
How it works
From connection to diagnosis in four steps
01
Connect the module
Place the adapter cable between the selected control module and the original vehicle harness. No permanent vehicle preparation is required.
02
Load our mapping
RFID loads the connectors, channels, components and permitted fault functions Breakoutbox has already mapped for this module.
03
Inject the fault
Select a component, channel or prepared scenario and activate the fault through Failure Simulation Studio.
04
Diagnose at the component
Observe the symptoms and measure at the real sensor or actuator using a Breakoutbox and Y-cable.
We map the module for you
Train from the component—not the ECU pin number.
We can map any electrical control module: ECU/ECM, BMS, BCM and more. We identify the relevant connectors and circuits, then link each usable pin to the real component and function it controls. You receive a custom adapter cable and a verified digital module profile—so trainees select components and faults, never anonymous pin numbers.
1
Analyse the module
We review reliable wiring information and connector data.
2
Map the relevant circuits
Every usable pin is linked to its component and function.
3
Build cable + profile
We create the physical adapter cable and verified digital profile.
4
Ready for training
Select components and faults—not pin numbers.
Electrical control modules we can map
ECU / ECMTCUBCMBMSABS / ESCEPSSRS / airbagVCUGatewayInverter / PCUOBC / DC-DCADAS controller
Water pump example
A mapped component becomes a simple software choice. Exact circuits vary by vehicle; the verified module profile contains the correct configuration for your application.
1 · Module connector
Power supplyExisting vehicle feed
GroundReturn path
PWM controlPump command
Speed / diagnosticFeedback to module
2 · Custom adapter cable
The cable brings the mapped module circuits safely through the FSB.
✓ RFID identified✓ Profile loaded
3 · FSB 2.0
FSB 2.0
Routes the selected mapped circuit through the correct fault function.
4 · Choose the fault
FSB Studio
ComponentWater pump
CircuitPWM control
FaultPoor contact
5 · Possible vehicle response
The real vehicle reacts to the real electrical condition.
Electric coolant pump slows down or stops
Temperature warning may appear
ECU stores a DTC; limp mode may be triggered
What happens: FSB 2.0 inserts resistance into the mapped PWM-control circuit. The vehicle experiences the same electrical condition as a deteriorated connector or wire—without changing the original harness.
Failure Simulation Studio
One workspace.
Every diagnostic case.
Every diagnostic case.
Module recognition, fault control, scenarios and session logging—locally on Windows.
Control every diagnostic case from one clear workspace
Automatic recognition
Load the correct cable and module profile through RFID.
Component-based navigation
Work from recognisable components instead of anonymous pin numbers.
Profile-controlled operation
Only supported fault functions are presented for the selected channel.
Multiple simultaneous faults
Control up to eight signal faults and two power faults.
Reusable scenarios
Repeat cases for lessons, examinations, demonstrations and validation.
Local session logging
Record activation, changes and clearing for review and documentation.
The Breakoutbox diagnostic ecosystem
Inject at the control module. Measure at the component.
FSB 2.0 creates the teachable problem. Breakoutbox and Y-cables provide the safe measurement path to solve it.
1
Inject
Create a controlled electrical fault at the ECU or other control module.
2
Observe
See the real warning lights, DTCs, driveability symptoms and component behaviour.
3
Measure
Use a Breakoutbox and Y-cable at the sensor or actuator without piercing wires.
4
Diagnose
Compare real measurements and identify the electrical root cause.
From FSB 1.0 to FSB 2.0
From manual fault creation to software-controlled scenarios
| Fault type | FSB 1.0 | FSB 2.0 |
|---|---|---|
| Open circuit / wire break | Manually switched | Activated and cleared through Failure Simulation Studio |
|
| |
| Short to ground | Manual banana jumper to harness ground | Controlled, protected and profile-validated |
| Series resistance / bad connection | Three fixed 10-turn potentiometers: 10 kΩ, 50 kΩ and 100 kΩ | Selectable programmed resistance resources |
| Power-line voltage drop | Limited manual setup | Controlled on mapped power-related channels |
| Poor ground | Limited manual setup | Controlled series resistance on validated ground channels |
| Sensor manipulation | External equipment required | Built in for supported signal channels |
| Pull-up / pull-down | External equipment required | Selectable resistance to validated supply or ground reference |
| Leakage to ground or supply | External equipment required | Controlled through selectable resistance |
| CAN/BUS resistance fault | Not built in | Available for validated CAN/BUS pairs |
| PWM manipulation | External equipment required | Built in for supported signal and actuator channels |
| Combined multi-channel scenario | Manual physical setup | Software-defined with resource and safety validation |
FSB 1.0 lets you create a fault. FSB 2.0 lets you create, control, repeat and document a complete diagnostic scenario.
For technical training
Practical diagnostics without sacrificing the vehicle
Give every student the same real diagnostic case without cutting wires or manually preparing the vehicle. Students still work with real symptoms, real components and real measurement tools.
- Faster lesson preparation
- Repeatable practical examinations
- Less risk of vehicle damage
- Real root-cause diagnosis
For vehicle development
Make electrical faults repeatable
Turn difficult field faults into controlled test conditions for ECU response validation, sensor and actuator testing, CAN investigations and regression testing.
- Real vehicle and module behaviour
- Controlled repeatable conditions
- Intermittent-fault reproduction
- One platform for development and training
Bring your module. We create the interface.
Stop preparing faults by hand
Tell us which vehicle, ECU, BCM, BMS or other electronic control module you want to support. We will help define the adapter cable, mapped profile and complete Breakoutbox measurement setup.
Request a launch consultation Email our engineering team