The 7th International Conferenceon Real-Time Simulation Technologies

Montreal | 9-12 June, 2014

Shuaijun Wu

Shanghai Keliang Information Tech. & Eng. Co.,Ltd.

The 7th International Conferenceon Real-Time Simulation TechnologiesMontreal | 9-12 June, 2014

BMS HIL testing

Background

Challenges of BMS testing

HIL Solution

Application Case

Benefits and Conclusion

The 7th International Conferenceon Real-Time Simulation TechnologiesMontreal | 9-12 June, 2014

Background—Energy Storage System

• Electric Vehicle/Hybrid Electric Vehicle

• Military Vehicle/Electric TankVehicle

• Energy storage SystemPower Grid

• Space Power

Aerospace

• Secondary Power Supply

Aviation

• Power Supply

Ship

The 7th International Conferenceon Real-Time Simulation TechnologiesMontreal | 9-12 June, 2014

Energy Storage System

Vehicle、Military：40~700V

10kW~200kW

Power Grid ESS：>1000V

>1MW

The 7th International Conferenceon Real-Time Simulation TechnologiesMontreal | 9-12 June, 2014

Trend

Trend1：Global burst in Energy Storage

Trend2:Burst in Advance Battery

The 7th International Conferenceon Real-Time Simulation TechnologiesMontreal | 9-12 June, 2014

Battery Management System(BMS)--- Brain of ESS !

Vehicle BMS:

BMS to be tested Battery packVehicle other parts

The 7th International Conferenceon Real-Time Simulation TechnologiesMontreal | 9-12 June, 2014

What a BMS does:

• battery pack voltage and current monitoring

• individual cell voltage measurements• cell balancing• state of charge estimating• cell temperature and health monitoring• while ensuring overall pack safety and

optimal performance• Communicating with other systems

The 7th International Conferenceon Real-Time Simulation TechnologiesMontreal | 9-12 June, 2014

Challenges of BMS testing

Testability

safety

repeatability

convenience

testing cost

Cell Monitoring Voltages of hundreds of cells, changing

Cell BalancingSimulating unbalanced states of cells, output/sink

balancing current

Extreme state/Fault stateBattery extreme load, over charge/discharge, aging,

short-circuit

Heat Management Simulate Battery temperature, changing

Different testing condition Change state of battery, (SOC, voltage, Temp.,)

Result/report Compare BMS results with actual value

Regression testing Create the same condition

The 7th International Conferenceon Real-Time Simulation TechnologiesMontreal | 9-12 June, 2014

Solution

Provide outputs of battery pack and cells

Calculate models,Control I/O, CAN

Real-time Simulator

BMS(Battery Management System)

Cell monitoring and state

estimating

Cell balancing

Temperature

Control, LDU

Charge/dis-charge control

Fault handling

Battery emulator

Model of VCU

Model of cooling,

insulation

Model of

charger and

motor

Model of

battery

Host PC

RT-Lab

CANCANI/O

User interface

The 7th International Conferenceon Real-Time Simulation TechnologiesMontreal | 9-12 June, 2014

What is a Battery Emulator

Output state of battery, including:

• Cell voltages

• Cell internal resistance

• Pack voltage

• Pack current

• Battery SOC

• Battery temperature

The 7th International Conferenceon Real-Time Simulation TechnologiesMontreal | 9-12 June, 2014

Battery Emulator structure

Modularized:

• Cell voltage module

• Battery temperature module

• Balancing current module

• FIU module

• Communication module

The 7th International Conferenceon Real-Time Simulation TechnologiesMontreal | 9-12 June, 2014

Characteristics:

• Able to simulate Cells of all kinds

• Able to connected in series

• Precision: voltage accuracy ±2mV

• High voltage isolation: 1500V

• Able to output & sink balancing current: ±1A

• Able to simulate battery temperature

• Provide fault simulation unit

• Controlled real-time

The 7th International Conferenceon Real-Time Simulation TechnologiesMontreal | 9-12 June, 2014

OP5600 Real-Time simulator

Functions:

• Model calculating

• Controlling battery emulator real-time

• Interact with BMS through I/Os

• Interact with BMS through CAN

• Interact with host PC through Ethernet

The 7th International Conferenceon Real-Time Simulation TechnologiesMontreal | 9-12 June, 2014

Battery Model——to simulate real battery characteristics

Equivalent Electric Circuit Model Real battery data

The 7th International Conferenceon Real-Time Simulation TechnologiesMontreal | 9-12 June, 2014

Application Case---China Fist Auto Work

The 7th International Conferenceon Real-Time Simulation TechnologiesMontreal | 9-12 June, 2014

Model

The 7th International Conferenceon Real-Time Simulation TechnologiesMontreal | 9-12 June, 2014

User interface:

PROVEtech:TA

RT-Lab

The 7th International Conferenceon Real-Time Simulation TechnologiesMontreal | 9-12 June, 2014

Benefits:

• Battery Simulation

• Provide variable battery state, difficult to realize using real battery

• Output & sink balancing current

• Safety

• Simulate fault state, high voltage & current, unsafe using real battery

• Systematic testing

• Testing automation, repeatable, testing case reuse

• Simulate all parts of vehicle, VCU, MCU, Charger, etc.

• Low Cost

• No real batteries waste

• Save developing and testing time

The 7th International Conferenceon Real-Time Simulation TechnologiesMontreal | 9-12 June, 2014

Conclusion:

• Energy Storage System Developing fast

• BMS plays an important role in ESS

• Full of challenges in BMS testing

• HIL solution with Real-time simulator & Battery Emulator

• Battery Emulator simulating battery cell

• Cells connected in series, up to 200 cells

• Realize systematic testing of BMS

• Turnkey solution & Engineering service----provided by Keliang

The 7th International Conferenceon Real-Time Simulation TechnologiesMontreal | 9-12 June, 2014