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Testing Energy Storage Systems:
From EVs to Utility Grid
© 2008 Bloomy Controls. All Rights Reserved
Jonathan P. Murray
Business Development Manager
Agenda
• Energy storage system landscape
• Electric vehicle battery simulation
• Utility grid storage performance testing
www.bloomy.com
• Utility grid storage performance testing
Bloomy Controls, Inc.
• Founded in 1992
• NI Select Alliance Partner
• Turnkey system development
• 16 Certified LabVIEW Architects
www.bloomy.com
• Offices:
• Windsor, CT
• Marlborough, MA
• Fairlawn, NJ
Bloomy Controls – Energy Focus
Provide test and data acquisition products
to battery, grid storage, and ground
transportation companies
www.bloomy.com3
Bloomy Controls – Energy Focus
Battery Packs
Battery Management System (BMS)
Battery Simulation / HIL
R&D
Characterization
Life cycle testing
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Battery Simulation / HIL
Battery Chargers
Utility Grid Energy Storage Systems
Life cycle testing
Functional Test
End of Line
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Energy storage system landscape
Energy Storage Systems (ESS)
Chemical
Biological
Electrochemical • Batteries
• Fuel cells
• Capacitors
Bloomy Controls’ Focus
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Electrical
Mechanical
Thermal
• Capacitors
• Superconductors
Types of Energy Storage Systems
Batteries: Capacity Range
Pacemaker Batteries
250W
Electric Vehicle Batteries
200kW
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Grid Storage Systems
2MW
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Global HEV / EV Projections
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Grid Energy Storage Growth
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Source: NanoMarkets' forecast for principal battery classes over the next eight years
Smart Grid: Energy Storage
Grid Energy Storage
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Vehicle to Grid
Smart grid stabilization system
Electric Vehicle ESS (battery)
ESS Components: Electric Vehicle
Battery Management System
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Battery Management System
Module 1 Module 2 Module X
Safety Auxiliaries
Utility Grid Energy Storage
ESS Components: Utility Grid
Control System
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BMS 1
Mod. 1 Mod. 2 Mod. x
BMS 2 BMS x Inverters AuxiliarySafety
Thermal
ESS Testing Challenges
• High Power Isolation
• Monitoring high voltages (EV: ~700VDC, Grid: > 1000VDC)
• Monitoring high currents (Grid: ~ 2000ADC)
• Noise
• Ensure accurate measurements
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• Ensure accurate measurements
• Reduce frequency injections
• Increase signal to noise ratio
• Synchronization
• Accurate power and energy calculations
• Ensure performance correlation
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www.bloomy.com
Electric vehicle battery simulation
”
Battery HIL Simulation System
“Provide a battery HIL system for the
evaluation of battery management
systems for hybrid tanks.
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”
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United States Army
Tank and Automotive
Research, Development,
and Engineering Center
HIL system to BMS connections
Battery Management System (BMS)
600V pack:
Up to 170 Series / Parallel stacked cells
Monitor & balance
Over voltage
Under voltage
Inrush current
Temperatures
Safety Interlocks
Fault Conditions
CAN
Serial, etc.
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GND
600VDC
Cell simulators
0.0 – 5.0V
10kΩ – 2MΩ
24V DIO
100mS timing
Custom
protocols
Battery HIL
Battery HIL Simulation: System
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Cell Simulation: Challenges
• Emulation of 176 independent cells
• 0-5V, 0.5mV resolution, ±0.1% accuracy
• 0-250mA, 0.2mA resolution , ±1% accuracy
• Flexible series / parallel stack connections
• 750V channel-to-channel isolation
Batteries are
inherently isolated
5V
600V
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• 750V channel-to-channel isolation
• 750V channel-to-ground isolation
• Cell Measurements
• High common mode voltages
• Thermal management
• Require space for air flow
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5V0V
5V5V
10V
5V
15V
595V
5V
Control
Common mode
voltage
Cell Simulation: Implementation
Isolation
• Output: Utilize high accuracy DC/DC converter and ensure cell
calibration can be performed
• Measurement: Use opto-isolators and high CMRR amplifiers
• Channel-to-channel: Ensure you meet the creepage and
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• Channel-to-channel: Ensure you meet the creepage and
clearance tolerances
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Utility grid energy storage
performance testing
Grid Storage Near-term Applications
• Load leveling and power quality systems to protect from brief
power interruptions
• Frequency regulation and stability for variability of renewable
energy sources
• Peak shaving to help manage electricity costs under variable
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0
200
400
600
800
1000
1200
Demand
Limit
Output
• Peak shaving to help manage electricity costs under variable
utility tariffs
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200
400
600
800
1000
1200
Demand
Limit
ESS power
Grid Storage Performance Testing
Requirements
• Test 25kW to 2MW systems
• 200+ mixed signal acquisition channels
• Evaluate performance for application-specific
operations cycles
• Analyze data and generate industry reports
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• Analyze data and generate industry reports
Grid Storage Performance Testing
Lab
Step Down
Transformer
ESS Control & Data Acquisition System
Application
Control Simulation
Utility Voltage
Source Simulation
Example Tests
• Interconnect tests
• Startup / Shutdown / E-Stop
• Equipment failure
• Abnormal Grid Events
• Performance testing
• Power Rating
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Battery
Racks
Battery
Management
System
Power
Conversion
System
Aux Power Panel Thermal Management
Master
Controller
ESS Control & Data Acquisition System • Power Rating
• Energy Rating
• Round trip efficiency
• Short / Long term test
• Application testing
• Frequency Regulation
• Peak Shaving
• Wind Farm Smoothing
Grid Storage: Test System Challenges
• System must accommodate many unique Energy Storage Systems with diverse connections and requirementsConfigurable
• Systems must measure multiple AC /DC voltages and currents, temperatures, flow, communications, etc.High signal count
• Up to 800VAC, 1200VDCHigh power
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• Up to 800VAC, 1200VDC
• Up to 2000AHigh power
• System needs to connect to all ESS components in a trailer
• All AC signals need to be synchronous (24+ channels)
Distributed and synchronous
• System must analyze power, energy, and other parameters
• Industry standard reports must be generate
Data management and reporting
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Grid Storage: General Signals
Parameter Name Channels Max Value Sampling
Rate (Hz)
Accuracy
AC Voltage 12 1200V 20.0k ±0.5%
AC Current 12 2000A 20.0k ±0.5%
DC Voltage 6 1200V 3.0k ±0.5%
DC Current 6 2000A 3.0k ±0.5%
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Power quality measurements: NEN-EN-IEC 61000-4-30
Monitoring electric power quality: IEEE Std 1159-2009
Distributed power resources: IEEE Std 1547.1-2005
DC Current 6 2000A 3.0k ±0.5%
DC Cell Voltages 96 14V 10 ±0.3%
Cell Temperatures 32 60 ºC 10 ±1.0%
Airflow 2 6000fpm 10 ±1.0%
Communications 2 CAN, Modbus, Ethernet
Grid Storage: Test System Overview
• 3 distributed containers with PXI RT chassis
• Low level signals with isolation transducers
• One amazing piece of software
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NI PXI hardware with isolation
PXI
Use highly accurate, synchronous data acquisition cards with
isolation transducersTip: No synch? Compensate in analysis
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±400mA
±500mA
Tip: Transducers = Isolation
Grid Storage: Signal Integrity
• Build Intelligent Cables to identify signal type
• Utilize twisted pair, shielded cables
• Select isolation transducers with current output
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Tip: Shield
Grid Storage: Highly Configurable
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Grid Storage: Data Analysis
Voltage and Current
Three Phase RMS (V & I)
Total Harmonic Distortion
Frequency Oscillation
Power and Energy
Three Phase or Total Power
Power Factor
Active Power
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Active Power
Apparent Power
Reactive Power
Energy Active Total
Energy Apparent Total
Energy Reactive Total
Power Quality
Over voltage and under voltage
Over current
Three Phase Voltage Harmonics
Wrap-up
• ISOLATION
• ISOLATION
• ISOLATION
• Pay special attention to the acquisition hardware
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• Pay special attention to the acquisition hardware
• High voltage / current can work with PXI using the correct
isolation transducers
• Use DIAdem when analyzing large amounts of data
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