Battery Cell Simulator

Transcription

1 Battery Simulator Main Part of a modular high-precision HiL-System for Battery Management Systems () Communication: Features supply range V up to (5, 0)* e.g. for E-Vehicle 90-0 ccuracy +/-500µV Electronic Load 0...5** (5, 0)* per cell ccuracy +/-m ctive and passive Balancing Current measurement +/-, accuracy +/-0µ -7 Coulomb measurement, accuracy +/-x0 s DUL/QUD mode for higher current Communication CN / EtherCT 00 MBit/s Desktop System e.g. for Chips 4 4 0HU System e.g. for Hybrid Drive 4-48 Comfortable calibration Up to 0 cells per rack, 00 cells in sum Integrated failure simulation BCS Mini 4, x Temperature sensor emulation 8HU System Efficiency, reliability and safety of modern lithium ion batteries for electric vehicle drives strongly depend on the battery management system () as their electronic control unit. The innovation by is a high-precision battery cell simulator (BCS), which offers complete function tests of the. Using this simulator, it is possible to adjust cell voltages in the range of V with an accuracy of +/-500µV even on currents up to. Each cell has an electronic load, which can be used for active and passive balancing. This constant current sink can generate currents of 0.5*. The comemso BCS comes with all accuracies directly at the test object, even in case of m cable length. In DUL or QUD mode currents at source up to 0 and at sink up to 0 at same accuracy can be used. Each cell provides a fault simulation for generating short circuits, cable breakage and change in polarity (reverse polarity). It is also possible to feed in two different external voltages via fault simulation per cell, e.g. KL0, KL. Each cell output additionally includes a high-precision current measurement system. This market innovation enables the BCS to detect balancing currents as well as leakage currents per cell, e.g. at a turned off. This way, deep discharges of whole battery modules can be analysed quickly. With the integrated Coulomb measurement per cell balancing procedures. The comemso Battery Simulator combines a high-precision emulation of battery cells with a high-resolution measurement technology and extended validation possibilities. -7 The comemso BCS combines battery cell emulation with measurement techniques. Communication takes place via CN or via EtherCT, for high-performance measurements and highly dynamic control even at > 0 cells. s an overheated battery is a high safety risk, the comemso test bench includes optional also highly accurate temperature sensor emulation cards. * DUL / QUD mode ** Uout > 4.5V ILoad =.5 max. Uout >.5V ILoad =.0 max. Uout >.5V ILoad =.5 max. Uout >.5V ILoad =.0 max. Copyright 0. lle Rechte vorbehalten.

2 Battery Simulator pplication virtual Battery with integrated failure simulation incl. Coulomb and leakage current measurement µ U R L Failure simulation Coulomb C N x N =...00 extended failure simulation unit FSU fg Battery Management System Test Process Temperature Sensor Emulation ϑ comemso_batteriezellen-simulator_flyer_eng_0504 Technical Data Communication CN bus / EtherCT Temperature range Lab conditions 5V/0V or CEE x6 Integrated emergency shutdown management Source: Isolation cell/communication Isolation cell/cell Simulation of up to 0 cells per rack mount of cells: 4 to 00 kv 60V Copyright 0. lle Rechte vorbehalten.

3 Battery Simulator Technical Data Overview CN / EtherCT Control Unit Voltage range: Nominal current: DC ccuracy: Ripple: Step response V à 4V: Step response 4V à V: Short-circuit-proof cell supply source per cell V 0.. (0.. 5, 0.. 0)* +/-0.5 mv +/- mv (fg = 5kHz) 4 ms.. 0 ms (depending on load) + V _ Low voltage area Nominal current: ccuracy: Constant Current internal electronic load per cell (0.. 5, 0.. 0)* +/-m yes electric failure simulation per cell Simulation of temperature sensors 0 Ohm...8 MOhm Resolution: Ohm ccuracy: +/-5ppm / C High voltage area up to 000V Broken wire Short circuit Polarity reversal External voltage supply (U, U, e.g. KL0, KL) ccuracy: measurement system per cell [m] ccuracy at -.. +: ccuracy at +.. +: +/- +/- m <0.4% measurement system per cell [µ] +/-0 m +/-0 µ Emulation of up to 00 cells * DUL / QUD mode ccuracy: Coulomb measurement per cell +/- * 50ms +/- * 0-7 s C Copyright 0. lle Rechte vorbehalten.

4 Battery Simulator Integrated Failure Simulation for each No. Test case failure simulation Sketch Realization Connecting of different cells to the BCS e.g. a sequenced connecting of the cells to the by the ECU connector Shortcut of one cell Defect of cell or failure on cell controller,... Polarity change of a cell BCS Mistake in cabling,... Test Bench extendable by further failure insulation, measurements and emulation BCS-Switchbox NTC/PTC Sensor Emulation High precision Battery Emulation High precision Coulomb Measurement Extended Failure Simulation VP for active balancing Service (Electrics, Mechanics) Safety Mechanisms Emergency- STOP, ϑ m mc fg Break-Out- Box, etc. Insulation monitoring, etc. µ µc (DUT) Copyright 0. lle Rechte vorbehalten. 4

5 Battery Simulator different possibilities for the connection Dynamic cabling with Break-Out-Box for 4 cells CS4-ISO-BOB CS-ISO-Node for single cell measurement for cell cascading Fix cabling to the CS4 connector set for 4 cells banana plug Sense Inputs Supply Outputs Included in Safety Drawer ECU-dapter for (e.g. in Safety Drawer) fast plug and play Version B Version fast exchange Copyright 0. lle Rechte vorbehalten. 5