Battery Management System Power Stage Hardware In-Loop Test Bench System Model 8630

Chroma introduces a new battery management system power stage hardware in the loop test bench system with equipment for battery management system related component characterization, including battery cell simulation, battery pack voltage and current simulation, temperature signal simulation, and provides a variety of hardware options for integration, such as DC power supply, digital meter, insulation meter, and so on.

Chroma 8630 battery management system power level hardware in-loop test system is specially designed for battery management system research and development, combining real-time system and open software architecture to provide users with flexible and powerful dynamic test system, which can be imported into the actual use of the situation for charging and discharging, dynamic voltage and current measurement and correction, battery balance test, CAN signal measurement and control, fault injection, insulation measurement and simulation of charging pile charging and other related test items. The system can be flexibly arranged and combined to simulate and verify the most important and highest risk of failure in the vehicle environment (e.g., communication and physical signal failures during cyclic discharging), so that more in-depth testing of the battery management system can be carried out without the need to test the actual vehicle or the actual battery packs, thus significantly improving development efficiency.

Chroma 8630 simulates the communication and operation of the complete system, which can simulate the fast dynamic charge/discharge flow of the battery pack, different cell conditions, temperature signals, system insulation impedance, etc., including the battery management system of the various protection function tests. It is equipped with a high-precision programmable power supply, which can be set or recorded according to any actual working conditions, covering a more comprehensive dynamic testing of the complete system.

The Chroma 8630 can simulate the dynamic pull-load and recharge behaviors of the power system, including cell balance current, battery high voltage and high current, and support Altair Activate vehicle model and various Simulink Model-Based real-time mathematical model import to achieve the international standard vehicle driving cycle, such as NEDC, WLTP, FTP-75, etc. In addition, it can also combine signal measurement and control, fault injection, insulation measurement, and simulate charging at the charging post to achieve the composite working condition. In addition, it can also combine signal measurement and control, fault injection, insulation measurement, and simulated charging at charging ports to achieve complex working conditions and deeper testing of the object under test.

Chroma 8630 battery management system power level hardware-in-the-loop (HIL) test system not only realizes the function and signal control tests required in the past, but also simulates the actual power behaviors such as cell balance current, high voltage and high current of the battery, and provides a more complete coverage of the test scope of high power components such as EVs or energy storage systems compared to the traditional signal level HIL solutions. It assists users to carry out more validation work for battery management system related components at the right end of the standard V-type development process, including system-level function and various composite working condition tests, so that problems can be identified and errors can be corrected at an early stage before entering into vehicle testing, effectively reducing development costs and improving testing efficiency.

In order to cover the complex behavior of the actual operation of various multi-vehicle, in recent years, the vehicle industry has been vigorously promoting ISO 26262 road vehicle functional safety specifications as a standard to be followed by vehicle manufacturers and their suppliers in product development, ISO 26262 from the product system down to the expansion of the hardware and software, for the safety requirements to comply with the contents of the requirements (Functional Safety Requirements → Technical Safety Requirements → Hardware Safety Requirements → Software Safety Requirements), and test verification part is mentioned, regardless of any functional safety integrity (ASIL) level, are required to carry out hardware in the loop and fault injection test to ensure that the safety mechanism is in place. Soft body safety requirements), and test verification part is mentioned, regardless of any functional safety integrity (ASIL) level, must be carried out in the hard body in the loop and fault injection test, in order to ensure that the safety mechanism in the vehicle level on the correctness and effectiveness of the failure coverage.

Chroma 8630 integrates an instant control system with a Fault Injection Unit to perform arbitrary open and short-circuit fault testing for various control and communication signals of the system under test, and can be combined with dynamic discharge, insulation impedance change and static charging...etc. to simulate and verify the most important and the highest risk of failure of the finished product. It can simulate the most important and highest risk of failure to verify the product's composite operation, and conduct more in-depth tests on the battery management system without the actual battery module, which not only improves the design of the product, but also matches the content of the fault injection test in the ISO 26262 process, which is conducive to obtaining the ASIL safety level certification.

Human-machine interface (UI Interface) is a very important part of the test system, which directly affects the operation convenience and execution efficiency of R&D testers. The Chroma 8630 system is pre-programmed to integrate all kinds of instruments and equipment to establish a control and test program development environment, which can be used by users to write and modify the test program, and also allows users to edit and modify the UI screen, so that the users can optimize the test project and process continuously. Users are allowed to edit and modify the UI screen, so that they can continuously optimize the test program and process.

Device and DUT parameter display screen:

Such as battery charging and discharging status, voltage, current, power, electricity, protection alarms, insulation degree ⋯, etc., and instantly update the values by means of digital, instrumentation and drawing.

The control parameter screen required for the test program:

Such as battery charging and discharging start-up and shutdown, charging and discharging voltage, current, insulation measurement start-up, fault injection signal selection, test condition selection, etc., and can change the control value by digital, drag and switch.