EV1077 Battery Cell Voltage Emulation Board

Simulating high-voltage batteries at cell level for system voltages of up to 1,000 V

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

  • Simulation of high-voltage batteries at cell level with a total voltage of up to 1,000 V
  • High-precision battery cell voltage emulation for use with a SCALEXIO system
  • Integrated electrical failure simulation

Application Areas

Testing battery management systems (BMS) requires the precise emulation of the voltage level of each individual cell of a battery pack.

For testing the BMS used in e-mobility and stationary applications, the four-channel EV1077 Battery Cell Voltage Emulation Boards are installed in a SCALEXIO hardware-in-the-loop (HIL) system and controlled by a dynamic battery simulation running on the HIL system. These test systems are ideal for testing BMS with system voltages of up to 1,000 V.

Key Benefits

The EV1077 Battery Cell Voltage Emulation Board emulates a controllable, highly precise terminal voltage for single battery cells. Depending on the battery type and the test focus, several boards can be used in one HIL system. 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.

Cell Emulation Setup

Cell voltage emulation is performed with several EV1077 boards. 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 ±0.5 mV across the entire working temperature range. The voltage is galvanically isolated, allowing the modules to be connected in series up to a maximum system voltage of 1,000 V.

The maximum current that can be supplied or sunk is 2 A, which enables testing of passive and active cell balancing strategies.

Hardware structure
  • 32 cells per 19" 3-U module
Output voltage
  • 0 ... 6 V
Resolution
  • 115 µV
Precision (across the working temperature range)
  • ±0.5 mV
Working temperature (environment)
  • 10 ... 50 °C (50 ... 122 °F)
Maximum current (sink/source)
  • 1 A
  • 2 A (optional)
Isolation
  • 60 V between the cells of a module
  • 1,000 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

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