Hardware-in-The-Loop Test Setup For Battery Management Systems
Kuusisto, Aki (2018)
2018
Sähkötekniikka
Tieto- ja sähkötekniikan tiedekunta - Faculty of Computing and Electrical Engineering
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Hyväksymispäivämäärä
2018-01-10
Julkaisun pysyvä osoite on
https://urn.fi/URN:NBN:fi:tty-201712182398
https://urn.fi/URN:NBN:fi:tty-201712182398
Tiivistelmä
Reduction of carbon dioxide emissions is one of the largest challenges of our society. Electric vehicles (EV) are one potential aspect of the solution to this challenge. EVs require energy storage, and lithium-ion (Li-ion) batteries are the best commercial solution at the moment. Li-ion batteries require management for both usability and safety. Battery management system (BMS) development and testing are demanding tasks, because EVs and other applicable systems are usually very complex products, and the successful management of the batteries is required for safe operation. Failure to keep the batteries within their safe operating parameters could result in broken equipment and even loss of life.
A Li-ion battery pack consists of battery cells and the BMS. Battery pack may consist of multiple modules of cells, and if the BMS is of a distributed construction, each module of cells has their own measuring card. Measuring card is in contact with the cells and supplies the voltage information to the main BMS via logic level signals. Both the cells and the measuring card may be mathematically modelled, which means that a real time simulation of them can be created. Using a programmable electronic control unit (ECU) to run the simulation and communicate with the BMS, a logic-level Hardware-In-the-Loop (HIL) system can be created, with the BMS as the hardware to be tested.
We created a model of battery modules on MathWorks Simulink software. The simulated modules run on a dSPACE MicroAutoBox II (MABX II) ECU. Simulation consists of individual cells and measuring cards, and it communicates with the BMS via Serial Peripheral Interface (SPI). Additional sensors and actuators are also simulated, and the simulation can be interacted with from the dSPACE ControlDesk software.
The BMS testing is safe and efficient with our HIL system. Going through the established test procedures is an order of magnitude faster than before, and some aspects of BMS functionality could be properly verified for the first time. Our system also found some new errors and potential faults in the tested BMS. HIL testing was found to be a useful solution for a BMS developer, and the tools offered by MathWorks and dSPACE to be most suitable for this type of a project.
A Li-ion battery pack consists of battery cells and the BMS. Battery pack may consist of multiple modules of cells, and if the BMS is of a distributed construction, each module of cells has their own measuring card. Measuring card is in contact with the cells and supplies the voltage information to the main BMS via logic level signals. Both the cells and the measuring card may be mathematically modelled, which means that a real time simulation of them can be created. Using a programmable electronic control unit (ECU) to run the simulation and communicate with the BMS, a logic-level Hardware-In-the-Loop (HIL) system can be created, with the BMS as the hardware to be tested.
We created a model of battery modules on MathWorks Simulink software. The simulated modules run on a dSPACE MicroAutoBox II (MABX II) ECU. Simulation consists of individual cells and measuring cards, and it communicates with the BMS via Serial Peripheral Interface (SPI). Additional sensors and actuators are also simulated, and the simulation can be interacted with from the dSPACE ControlDesk software.
The BMS testing is safe and efficient with our HIL system. Going through the established test procedures is an order of magnitude faster than before, and some aspects of BMS functionality could be properly verified for the first time. Our system also found some new errors and potential faults in the tested BMS. HIL testing was found to be a useful solution for a BMS developer, and the tools offered by MathWorks and dSPACE to be most suitable for this type of a project.