opal-rt rt14: bms hil testing
DESCRIPTION
Baterry Manangement System HIL Testing, by Keliang and OPAL-RTTRANSCRIPT
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The 7th International Conferenceon Real-Time Simulation Technologies
Montreal | 9-12 June, 2014
Shuaijun Wu
Shanghai Keliang Information Tech. & Eng. Co.,Ltd.
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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
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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
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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
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The 7th International Conferenceon Real-Time Simulation TechnologiesMontreal | 9-12 June, 2014
Trend
Trend1:Global burst in Energy Storage
Trend2:Burst in Advance Battery
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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
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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
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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
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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
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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
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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
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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
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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
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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
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The 7th International Conferenceon Real-Time Simulation TechnologiesMontreal | 9-12 June, 2014
Application Case---China Fist Auto Work
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The 7th International Conferenceon Real-Time Simulation TechnologiesMontreal | 9-12 June, 2014
Model
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The 7th International Conferenceon Real-Time Simulation TechnologiesMontreal | 9-12 June, 2014
User interface:
PROVEtech:TA
RT-Lab
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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
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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
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The 7th International Conferenceon Real-Time Simulation TechnologiesMontreal | 9-12 June, 2014