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BMS HIL TEST SYSTEM

Real-time battery pack simulation

The BMS Hardware-in-the-Loop (HIL) Test System is a high performance platform providing all necessary input signals used for battery pack simulation.  A real-time operating system executes complex cell and pack models commonly used for BMS algorithm development and firmware regression testing.

  • Over 200 series connected cell voltage simulation
  • Pack voltage simulation up to 1000Vdc
  • Current and temperature sensor simulation
  • BMS control IO and communication simulation
  • Fault insertion and auxiliary system measurements
  • Custom cell and pack model integration (Simulink, C++, LabVIEW, etc.)
  • Software application for manual operation, automated test, and reporting

Use this form to configure your
Battery Pack Simulator

Battery Pack Simulator Configurator

 

The Battery Management Systems (BMS) Hardware-in-the-Loop (HIL) Test System provides a safe and efficient method for engineers to test BMS algorithms and system performance during the early stages of development for applications such as:

  • Electric Vehicles/Plug-in HEVs
  • High Power UPS/Grid Energy Storage Systems
  • General Purpose Multi-cell Battery Stacks

Bloomy has designed a modular and configurable platform to accommodate the variety of battery input signals such as cell counts, sensors, IO, and communications required to simulate a BMS test atmosphere. Depending on the channel count, systems can range from a mobile industrial enclosure with high voltage safety to a desktop unit. The system software is a customized application built on the National Instruments VeriStand real-time test software environment, providing methods for configuring system models and test environment.

Trying to validate a BMS and perform environmental testing?

Visit the BMS Validation System

The BMS HIL Test System is a modular platform, providing a unique configuration to test individual BMS devices and functionality.

BMS HIL Test System

The BMS HIL Test System is the ideal platform to use when developing and testing a real-time embedded controller, benefits include:

  • Provides a safe and efficient method of simulating a high voltage battery
  • Implements irregular and dangerous physical battery conditions
  • Improves quality of testing with repeatable stimulus
  • Reduces test duration and cost by not using physical batteries
  • Shortens development process through executing known test scenarios

The following specifications are standard. Systems can be customized to accommodate your requirements.

Cell Channel Simulation
Number of Channels

12 / module

Max number of Modules20 (240 channels @ 4.2V)
Channel TypeSink and Source
Voltage Range per cell0.0 to 5.0 V
Voltage Resolution0.1 mV
Voltage Accuracy (Requires Remote Sense)±3 mV
Balancing Current Range*± 500.0 mA; output derates linearly under 2 V
Current Resolution0.1 mA
Current Accuracy±4 mA
Current Limiting Accuracy±10 mA
Common mode isolation1000 VDC CH-TO-CH, CH-TO-GND

 

Cell Channel Readback
Voltage Resolution0.1 mV
Voltage Accuracy±3 mV
Current Resolution0.1 mA
Current Accuracy±4 mA

 

Temperature Sensor Simulation
Typical Signal Type*Resistance (Thermistor / RTD)
Number of Channels12 / module
Range10Ω to 500 kΩ
Resolution
Accuracy1%
Additional Signal TypesAnalog voltage (± 10V)

 

Analog current (0 – 40mA)

 

Current Sensor Simulation
Typical Signal TypeAnalog voltage
Number of Channels2 channel
Range± 10V
Resolution16 bit
Accuracy± 0.5%
Additional Signal TypesHigh accuracy (±2V) analog signals

CAN communications

 

BMS Bus Voltage Simulation
Number of Channels2 channel
Voltage Range*0 to 60V
Current Range*0 to 20A
Power Range850W

 

Communication Protocols
Standard ProtocolHigh-Speed CAN
Number of Ports2
Baud Rate40 kbits/s to 1Mbit/s
Additional ProtocolsLIN, SPI, RS232, Modbus

 

Pack Voltage Simulation
Number of Channels1 channel
Voltage Range*up to 1000VDC
Current Range*1.5ADC
Programming Accuracy± 0.075% of full scale

 

BMS Control IO
Number of Channels24 input / 24 output
Voltage Range0 to 60V
Voltage Low Logic Level1VDC
Voltage High Logic LevelMin: 3.2VDC, Max: 60VDC
Common mode isolation60V channel-to-channel

* Do you have special requirements for cell, bus, or pack voltage or current; isolation , temperature simulation, or communications? Contact us. 

Bloomy use the latest versions of the National Instruments VeriStand and LabVIEW development environments to customize the application software based on final system hardware.  Because all BMS units are unique, Bloomy has developed system level components to facilitate platform scalability and supportability to reduce software customization.  Major application features:

  • Graphical User interface: to ensure you get the most out of the system, a customized interface is provided to view full system status and perform all system control, test, report viewing, and configuration.
  • Manual Control: complete operation of system channels and allows for value forcing, alarming, calibration, and stimulus generation.
  • Automated Test: fully automated test environment, providing the ability to generate stimulus profiles (drive profiles) and test scenarios to complete BMS firmware regression testing.
  • Communication Integration: integrate standard CAN and LIN automotive diagnostics or implement custom communication protocols used as feedback into models or measurement and reporting channels.
  • Reporting: create test reports for system IO, communication capturing during manual or automated control.
  • System Configuration: store all necessary hardware configuration information, software variables, IP address, report folders, model location, test stimulus profiles, and other critical station information.
  • Model Execution: save, recall, and load custom models. Model execution is dependent on system IO, channel count, feedback, and the model itself. Typical pack model execution (complete system IO) is between 10Hz and 500Hz. Benchmarking is available.