opal-rt rt14: bms hil testing
DESCRIPTION
Baterry Manangement System HIL Testing, by Keliang and OPAL-RTTRANSCRIPT
The 7th International Conferenceon Real-Time Simulation Technologies
Montreal | 9-12 June, 2014
Shuaijun Wu
Shanghai Keliang Information Tech. & Eng. Co.,Ltd.
The 7th International Conferenceon Real-Time Simulation TechnologiesMontreal | 9-12 June, 2014
BMS HIL testing
Background
Challenges of BMS testing
HIL Solution
Application Case
Benefits and Conclusion
The 7th International Conferenceon Real-Time Simulation TechnologiesMontreal | 9-12 June, 2014
Background—Energy Storage System
• Electric Vehicle/Hybrid Electric Vehicle
• Military Vehicle/Electric TankVehicle
• Energy storage SystemPower Grid
• Space Power
Aerospace
• Secondary Power Supply
Aviation
• Power Supply
Ship
The 7th International Conferenceon Real-Time Simulation TechnologiesMontreal | 9-12 June, 2014
Energy Storage System
Vehicle、Military:40~700V
10kW~200kW
Power Grid ESS:>1000V
>1MW
The 7th International Conferenceon Real-Time Simulation TechnologiesMontreal | 9-12 June, 2014
Trend
Trend1:Global burst in Energy Storage
Trend2:Burst in Advance Battery
The 7th International Conferenceon Real-Time Simulation TechnologiesMontreal | 9-12 June, 2014
Battery Management System(BMS)--- Brain of ESS !
Vehicle BMS:
BMS to be tested Battery packVehicle other parts
The 7th International Conferenceon Real-Time Simulation TechnologiesMontreal | 9-12 June, 2014
What a BMS does:
• battery pack voltage and current monitoring
• individual cell voltage measurements• cell balancing• state of charge estimating• cell temperature and health monitoring• while ensuring overall pack safety and
optimal performance• Communicating with other systems
The 7th International Conferenceon Real-Time Simulation TechnologiesMontreal | 9-12 June, 2014
Challenges of BMS testing
Testability
safety
repeatability
convenience
testing cost
Cell Monitoring Voltages of hundreds of cells, changing
Cell BalancingSimulating unbalanced states of cells, output/sink
balancing current
Extreme state/Fault stateBattery extreme load, over charge/discharge, aging,
short-circuit
Heat Management Simulate Battery temperature, changing
Different testing condition Change state of battery, (SOC, voltage, Temp.,)
Result/report Compare BMS results with actual value
Regression testing Create the same condition
The 7th International Conferenceon Real-Time Simulation TechnologiesMontreal | 9-12 June, 2014
Solution
Provide outputs of battery pack and cells
Calculate models,Control I/O, CAN
Real-time Simulator
BMS(Battery Management System)
Cell monitoring and state
estimating
Cell balancing
Temperature
Control, LDU
Charge/dis-charge control
Fault handling
Battery emulator
Model of VCU
Model of cooling,
insulation
Model of
charger and
motor
Model of
battery
Host PC
RT-Lab
CANCANI/O
User interface
The 7th International Conferenceon Real-Time Simulation TechnologiesMontreal | 9-12 June, 2014
What is a Battery Emulator
Output state of battery, including:
• Cell voltages
• Cell internal resistance
• Pack voltage
• Pack current
• Battery SOC
• Battery temperature
The 7th International Conferenceon Real-Time Simulation TechnologiesMontreal | 9-12 June, 2014
Battery Emulator structure
Modularized:
• Cell voltage module
• Battery temperature module
• Balancing current module
• FIU module
• Communication module
The 7th International Conferenceon Real-Time Simulation TechnologiesMontreal | 9-12 June, 2014
Characteristics:
• Able to simulate Cells of all kinds
• Able to connected in series
• Precision: voltage accuracy ±2mV
• High voltage isolation: 1500V
• Able to output & sink balancing current: ±1A
• Able to simulate battery temperature
• Provide fault simulation unit
• Controlled real-time
The 7th International Conferenceon Real-Time Simulation TechnologiesMontreal | 9-12 June, 2014
OP5600 Real-Time simulator
Functions:
• Model calculating
• Controlling battery emulator real-time
• Interact with BMS through I/Os
• Interact with BMS through CAN
• Interact with host PC through Ethernet
The 7th International Conferenceon Real-Time Simulation TechnologiesMontreal | 9-12 June, 2014
Battery Model——to simulate real battery characteristics
Equivalent Electric Circuit Model Real battery data
The 7th International Conferenceon Real-Time Simulation TechnologiesMontreal | 9-12 June, 2014
Application Case---China Fist Auto Work
The 7th International Conferenceon Real-Time Simulation TechnologiesMontreal | 9-12 June, 2014
Model
The 7th International Conferenceon Real-Time Simulation TechnologiesMontreal | 9-12 June, 2014
User interface:
PROVEtech:TA
RT-Lab
The 7th International Conferenceon Real-Time Simulation TechnologiesMontreal | 9-12 June, 2014
Benefits:
• Battery Simulation
• Provide variable battery state, difficult to realize using real battery
• Output & sink balancing current
• Safety
• Simulate fault state, high voltage & current, unsafe using real battery
• Systematic testing
• Testing automation, repeatable, testing case reuse
• Simulate all parts of vehicle, VCU, MCU, Charger, etc.
• Low Cost
• No real batteries waste
• Save developing and testing time
The 7th International Conferenceon Real-Time Simulation TechnologiesMontreal | 9-12 June, 2014
Conclusion:
• Energy Storage System Developing fast
• BMS plays an important role in ESS
• Full of challenges in BMS testing
• HIL solution with Real-time simulator & Battery Emulator
• Battery Emulator simulating battery cell
• Cells connected in series, up to 200 cells
• Realize systematic testing of BMS
• Turnkey solution & Engineering service----provided by Keliang
The 7th International Conferenceon Real-Time Simulation TechnologiesMontreal | 9-12 June, 2014