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Battery Cell Voltage Emulation

Additional hardware for HIL simulation

For the HIL test for battery management systems (BMS), dSPACE provides the high-precision EV1077 Battery Cell Voltage Emulation Board. The board makes it possible to simulate high-voltage batteries at cell level.

For the HIL test for battery management systems (BMS), high-voltage batteries have to be simulated at cell level. To make this possible dSPACE provides the high-precision EV1077 Battery Cell Voltage Emulation Board. Due to its compact size, up to 32 cells can be combined in one 19'', 3-U module or up to 128 cells in a 19'', 12-U rack.

EV1077 Battery Cell Voltage Emulation Board 1)
Hardware structure
  • 32 cells per 19" 3-U module
Output voltage
  • 0 ... 6 V
Resolution
  • 120 µV
Precision (across working temperature range)
  • ±1.5 mV
Working temperature (environment)
  • 10 ... 50 °C
Maximum current (sink/source)
  • 1 A, switchable in parallel
Isolation
  • 60 V between the cells of a module
  • 1000 V between the cells and the environment
Connection
  • Ethernet, e.g., as interface to SCALEXIO
Maximum update rate for all cells
  • 1 kHz
Fault simulation
  • Broken wire between ECU and battery
  • Short circuits between cells

 

1) Technical modifications possible.

Cell voltage emulation is performed with several EV1077s. The number of these controllable buffer amplifier boards is configured to match the battery type. The boards supply a continuously adjustable voltage, in the range 0 to 6 V. This relatively wide range means that damaged cells can be emulated. For example, a voltage higher than the nominal voltage simulates a cell's increased internal resistance during charging.
The voltage is output with a precision of ±1.5 mV across the entire working temperature range, and with a precision of better than ±1 mV within a reduced temperature range. The voltage is galvanically isolated, allowing the modules to be connected in series up to a voltage of 800 V. A reference value step is corrected completely in less than 500 µs. Fast data transmission means that a change to all the cell's voltages takes less than 1 ms.
The maximum current that can be supplied or sunk is 1 A, which enables testing of passive and active cell balancing strategies. For special requirements, up to four modules can be connected in parallel to quadruple the maximum current. dSPACE's Automotive Simulation Models are ideal battery simulation models.

For battery management solutions, dSPACE offers compact systems with one 19'' full-size simulator rack including all required components. The systems contains:

  • Up to 200 cells for battery voltage emulation
  • The real-time computing system
  • A safety compartment for the ECU

To meet safety regulations, a safety compartment prevents accidental contact with the ECU, preventing harm due to high voltages. With everything combined in one system, users do not have to think about the ECU connection, but can concentrate on their project.