Advanced cell simulation for passive- and active-balancing BMS testing
The Advanced Battery Simulator 800 (ABS) provides eight 5V, 5A cells to simulate battery sink and source characteristics for testing Battery Management Systems (BMS). Over 200 cells can be stacked in series to safely simulate battery stacks of up to 1000 VDC. Built-in voltage and current readback sensing per cell provide highly accurate simulation as well as live data readings without external monitoring equipment. Onboard auxiliary I/O can be used to simulate cell and module temperature sensors and provides additional analog and digital I/O. Integrated faulting relays facilitate open circuit, cell short, and reverse polarity faults, with a dedicated "BMS" output line to ensure faulting does not break the cell stack. Safe operation is guaranteed by certification to the IEC 61010 product safety standard and the use of robust, reinforced/double insulation between the high voltage cell domains and the low voltage communication interfaces and auxiliary IO domains.
- 8 independently controlled cell channels
- 0 to 5 VDC output, sink/source up to 5A/Ch
- <0.5mV voltage accuracy
- 1000 VDC Ch-to-Earth GND isolation
- 1000 VDC Ch-to-Ch isolation
- 1U form factor for high cell density
- Certified to IEC 61010-1, -2
- Built-in fault insertion per cell (open, short, reverse polarity)
- Dedicated BMS terminal per cell
- Auxiliary ±10V analog and 5V digital I/O
- Voltage-based temperature simulation per cell
- TCP/IP, UDP, RS-485, and high-speed CAN control communications
- C/C++, Python, & NI LabVIEW™ drivers
- CAN .dbc file
- Onboard cell equivalent circuit modeling
The Advanced Battery Simulator 800 (ABS) can be used as a standard instrument, controllable via TCP/IP, UDP, CAN, or RS-485 via the supplied C/C++, Python, LabVIEW™ drivers. The ABS can also be integrated into hardware-in-the-loop (HIL) and real-time environments using the supplied CAN .dbc files. Whether controlled via standard SCPI commands for automated production test, or via real-time CAN for HIL validation, the ABS is the fundamental building block of many advanced BMS automated test solutions.
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The Advanced Battery Simulator 800 (ABS) introduces a new level of flexibility and safety to the laboratory environment with built-in fault modes for each cell! Each of the ABS’s simulated cells has one normal state and three fault states:
Normal: In normal operation, all terminals of each cell remain connected. The battery management system (BMS) or other unit under test is able to sense each cell’s state and to control cell balancing and other pack characteristics.
Open-Wire: During an open-wire fault state, the ABS physically disconnects the simulated cell’s battery management system terminal. This fault simulates the real-world condition of a broken sense wire. The simulated battery pack’s other connections may or may not remain intact during this fault depending on how the BMS and ABS are connected.
Short-Circuit: The short-circuit fault state causes the ABS to apply a physical short circuit between the cell’s negative terminal and the cell’s BMS terminal. This condition may arise, for example, through abrasion or when insulation melts in an overheated battery pack.
Reverse Polarity: The ABS reverses the polarity of the simulated battery cell when the cell is in this fault condition. A battery can acquire a negative polarity if the BMS has allowed a completely discharged cell to become charged by other cells, thus acquiring a negative charge.
Using the built-in faulting capability of the ABS ensures the utmost safety and reliability of your product.
