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Christian NiklasAIT Austrian Institute of Technology, Austria

Functional Validation of Battery Management Systems

“eMobility eMotion”25-26th September 2013, Toulouse, France

European Conference on Nanoelectronics and Embedded Systems for Electric Mobility

© 2013. AIT Austrian Institute of Technology GmbH. All rights reserved. Any distribution or copy is subject to prior written approval by AIT

Outline

Introduction Safety-related BMS-Functions HIL-Testbench Approach Challenges in Testing BMS HIL-Simulation Setup for CAN and SPI Networks Conclusion

226.09.2013 NESEM Conference, Toulouse


Introduction

Battery Management Systems objectives Ensure safe operation Battery diagnostics

Communication Vehicle Control Unit (VCU) On-board charger/charging equipment (OBC)

326.09.2013

VCU

BMSMCUOBC

GW

ECU

-+

NESEM Conference, Toulouse

© 2013. AIT Austrian Institute of Technology GmbH. All rights reserved. Any distribution or copy is subject to prior written approval by AIT© 2013. AIT Austrian Institute of Technology GmbH. All rights reserved. Any distribution or copy is subject to prior written approval by AIT

Safety-related BMS Functions

BMS safety goals

Follow switch-off/on request from the charging device

Related BMS functions Charging request monitoring Vehicle-CAN communication Relay control




BMS safety goals


Overcharge of battery cell(s) shall be avoided

Related BMS functions Charging request monitoring Vehicle-CAN communication Relay control Battery current monitoring




BMS safety goals



Over-temperature of battery cells shall be avoided

Related BMS functions Charging request monitoring Vehicle-CAN communication Relay control Battery current monitoring Temperature monitoring Thermal management Battery module communication




BMS safety goals




Over/Under-voltage of battery cells shall be avoided

Related BMS functions Charging request monitoring Vehicle-CAN communication Relay control Battery current monitoring Temperature monitoring Thermal management Battery module communication Voltage monitoring




BMS safety goals




Over/Under-voltage of battery cells shall be avoided

Open contactors in case of an isolation fault

…

Related BMS functions Charging request monitoring Vehicle-CAN communication Relay control Battery current monitoring Temperature monitoring Thermal management Battery module communication Voltage monitoring Isolation monitoring …



Sensor System Allocation

Safety-related BMS functions Charging request monitoring Relay control Battery current monitoring Voltage monitoring Temperature monitoring Thermal management Isolation monitoring


Battery Management System

Isolation Monitoring

Module

Power Distribution

Module

Battery Modules

Cooling System

sensor network (SPI / CAN)

vehicle CAN

On-board Charger

I/O


Isolation Monitoring

Module

Power Distribution

Module

Battery Modules

Cooling System

simulated bus

physical bus

simulated bus physical bus

On-board Charger

I/O

I/O

HIL-Testbench Approach


virtual subsystem real subsystem

Benefits Safe testing environment Automated tests Flexible design Reproducible test results No cell emulators needed

Limits Initialization timing Quality of validation

relies on the accuracy of the battery model

Battery Management System


Challenges in Testing BMS

Full-size virtual battery simulation Simulation of complete cell string Balancing behaviour Realistic thermal behaviour

Sensor network simulation Interfacing the BMS on the used sensor network for battery module

communication (SPI / CAN) Data refreshment timing

Vehicle network Remainig-bus simulation on vehicle network Interfacing the EVSE



HIL-Simulation Setup for CAN Networks

« Test Scenarios« Model Execution« Report Generation


simulated battery internal bus

Matlab/Simulink

Simulink model of a battery cell

Isolation Monitoring Module

Power Distribution Module

Cooling SystemHIL Interface

Battery Modules

Simulink Model

Embedded Code Embedded Code Embedded CodeCAN I/O CAN

vehicle CAN bus

I/O

CAN sensor network


HIL-Simulation Setup for SPI Networks

« Test Scenarios« Model Execution« Report Generation


simulated battery internal bus

Matlab/Simulink

Simulink model of a battery cell

vehicle CAN bus

I/O

Isolation Monitoring Module

Power Distribution Module

Cooling SystemHIL Interface

Battery Modules

Simulink Model

Embedded Code Embedded Code Embedded CodeEthernet I/O CAN

SPIEthernet Balancer Emulator


Balancer Emulator

Objective Instantiation of several balancer chips Addressable via slave select and/or

configured chip address Real response time

Theory of Operation(1) Balancer emulator requests

cell voltages update(2) Addressed instance requests

data refreshment from HIL(3) HIL simulation calculates new values

and transmits it to the emulator(4) Balancer instance responds

to BMS command with new data


BalancerEmulator

HIL Interface

(2)

(4)

(3)

ensu

re re

al

resp

onse

tim

e be

havi

our

x Instances

(1)

busy

new data


Conclusion

Functional Validation of Battery Management Systems in a safe and affordable manner leads across the simulation of the battery internal communication network

Solution provides support for SPI and CAN

Still no need to invest in expensive Cell emulators

No limitation for Smart Charging simulations via PLC to address V2G applications


Thank you for your attention

ContactChristian Niklas

Austrian Institute of TechnologyElectric Drive TechnologiesVienna | [email protected] | www.ait.ac.at

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