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Jorge Varela Barreras, David A. HoweyDepartment of Engineering ScienceUniversity of Oxford
users.ox.ac.uk/~engs1053/
State-of-the-art of Hardware-in the-loop Solutions for BatteryManagement System Testing
HVM CATAPULT: Energy Storage ConferenceInternational Digital Laboratory
24th Sep. 2015
LIFETIMELIMITED
COSTLIMITED
R&DKEY
TAKEAWAY
HIGHEREFFICENCY AND
LIFETIME
Facts about LIB
19911st cell
by Sony
2nd
MARKETafter lead
acid
2013+15 bi US$REVENUE*
HIGHERSPECIFIC ENERGY
AND POWER
NOMEMORYEFFECT
SOALIMITED
2020+75 bi US$REVENUE*
*Source: Foster & Sullivan
HVM CATAPULT: Energy Storage ConferenceInternational Digital Laboratory
24th Sep. 2015
LIFETIMELIMITED
COSTLIMITED
R&DKEY
TAKEAWAY
HIGHEREFFICENCY AND
LIFETIME
Facts about LIB
19911st cell
by Sony
2nd
MARKETafter lead
acid
2013+15 bi US$REVENUE*
HIGHERSPECIFIC ENERGY
AND POWER
NOMEMORYEFFECT
SOALIMITED
2020+75 bi US$REVENUE*
*Source: Foster & Sullivan
BMSREQUIRED
DIS/CHARGEMANAGEMENT
DIAGNOSISDIAGNOSISSOC, power
capability SOH,SOF…
PROTECTIONAGAINST HAZARDS
MONITORING
MANAGEMENTDATA
MANAGEMENT
HVM CATAPULT: Energy Storage ConferenceInternational Digital Laboratory
24th Sep. 2015
MonitoringProtection againstProtection against
hazardsCharge/discharge management Diagnosis
Datamanagement
High-level representation of BESS
BMSREQUIRED
A BMS can be defined as a group of related HW and SW units, dedicated to deal with or
to control the performance of a battery according to certain set of principles or procedures
High-levelrepresentation of a
BESS
HVM CATAPULT: Energy Storage ConferenceInternational Digital Laboratory
24th Sep. 2015
Advanced BMS functional tree
MonitoringProtection againstProtection against
hazardsCharge/discharge management Diagnosis
Datamanagement
Manage the batteryBMS
REQUIRED
C. Fleischer, J. V. Barreras et al., “Development of software and strategies for Battery Management System testing onHIL simulator,” Proceedings of the 2016 Eleventh International Conference on Ecological Vehicles and RenewableEnergies (EVER). Monte-Carlo: IEEE Press, 2016.
HVM CATAPULT: Energy Storage ConferenceInternational Digital Laboratory
24th Sep. 2015
BMS HW & SW development
V-model
INTEGRATION
TESTSREQUIRED
DURINGINTEGRATION
BMSPRODUCT
MANAGEMENTREQUIRED
C. Fleischer, J. V. Barreras et al., “Development of software and strategies for Battery Management System testing onHIL simulator,” Proceedings of the 2016 Eleventh International Conference on Ecological Vehicles and RenewableEnergies (EVER). Monte-Carlo: IEEE Press, 2016.
HVM CATAPULT: Energy Storage ConferenceInternational Digital Laboratory
24th Sep. 2015
Challenges of BMS testing
Source: Shanghai Keliang Information Tech. & Eng. Co., Ltd.
HVM CATAPULT: Energy Storage ConferenceInternational Digital Laboratory
24th Sep. 2015
BMS testing: real vs virtual battery
BMSREQUIRED
PROBLEMREAL LIB
Cost and time effectiveness, feasibility, reproducibility and risksbeyond the normal range of operation, at early stages in the
BMS development process or during fault simulation
Need to test BMS controller HW and SW at system level
BMS testing in advanced HIL simulator
HVM CATAPULT: Energy Storage ConferenceInternational Digital Laboratory
24th Sep. 2015
c. 2010COMMERCIALSOLUTIONS
COMPLEXSYSTEMS
HIGHMODULARITY
Custom made SW solutions:
Simulink, MappleSim, C++, LabView…
RT-Lab, ControlDesk, ConfigurationDesk…
+ Controllable DC voltage source
(for BMS powering or pack voltage simulation)
FIU on/off-board
State-of-the-art of HIL simulator
HVM CATAPULT: Energy Storage ConferenceInternational Digital Laboratory
24th Sep. 2015
FIUon/off-board
State-of-the-art of HIL simulator
C. Fleischer, J. V. Barreras et al., “Development of software and strategies for Battery Management System testing onHIL simulator,” Proceedings of the 2016 Eleventh International Conference on Ecological Vehicles and RenewableEnergies (EVER). Monte-Carlo: IEEE Press, 2016.
HVM CATAPULT: Energy Storage ConferenceInternational Digital Laboratory
24th Sep. 2015
Other
State-of-the-art of HIL simulator
Common mode isolation in order of +1 kV DC CH-TO-CH, CH-TO-GND
Temperature and current sensor emulation, typ. range +/- 10V and
accuracy around ± .1 / 1 %
Cell voltageemulator
No. of channels from a few up to +200
Accuracy in order of mV: +/- 0.5 / 1 / 3 mV
Max. update rate for all cells up to 1 kHz, i.e. not sufficient for certain test
High voltage resolution, in order of .1 mV
Range from around 0 to + 5 / 6 / 8…V
Balancingcurrent
Balancing current range +/- 0.5 / 1 / 2.5 / 3 A and w/ parallelization up to 10 A
Balancing current accuracy in order of mA: +/- 1 / 2 / 4 mA
High balancing current resolution, in order of .1 mA
GENERAL SPECS
HVM CATAPULT: Energy Storage ConferenceInternational Digital Laboratory
24th Sep. 2015
Application case – dSPACE HILS
J. V. Barreras et al., “An Advanced Hardware-in-the-loop Simulation Battery Model for Battery Management Systemtesting,” IEEE Transactions on Industry Applications, 2016, to be published.
sBMS v6Lithium Balance
Commercial
BMSSystem level
tests
HVM CATAPULT: Energy Storage ConferenceInternational Digital Laboratory
24th Sep. 2015
Custom battery system model
J. V. Barreras et al., “An Advanced Hardware-in-the-loop Simulation Battery Model for Battery Management Systemtesting,” IEEE Transactions on Industry Applications, 2016, to be published.
HVM CATAPULT: Energy Storage ConferenceInternational Digital Laboratory
24th Sep. 2015
Custom battery system model
J. V. Barreras et al., “An Advanced Hardware-in-the-loop Simulation Battery Model for Battery Management Systemtesting,” IEEE Transactions on Industry Applications, 2016, to be published.
HVM CATAPULT: Energy Storage ConferenceInternational Digital Laboratory
24th Sep. 2015
Custom battery system model
J. V. Barreras et al., “An Advanced Hardware-in-the-loop Simulation Battery Model for Battery Management Systemtesting,” IEEE Transactions on Industry Applications, 2016, to be published.
Fuse and switch box model
HVM CATAPULT: Energy Storage ConferenceInternational Digital Laboratory
24th Sep. 2015
Custom battery system model
LIB pack electro-thermal model coupled with aging model
40 AhKokam
NMC-cathode
Modelling approach
Equivalent Circuit Model approachSOC, temperature and ageing dependencies
Impedance-based model + thermal model + aging model
Characterization techniques
Pulse power characterizationOCV test and Capacity check
Electrochemical impedance spectroscopy (EIS)Anisotropic thermal diffusivity test
Life degradation
Accelerated cycling with a real driving cycle andconducting RPT every 100 cycles
HVM CATAPULT: Energy Storage ConferenceInternational Digital Laboratory
24th Sep. 2015
Custom battery system model
HVM CATAPULT: Energy Storage ConferenceInternational Digital Laboratory
24th Sep. 2015
Custom battery system model
LIB electro-thermal cell model validation in simulation
J. V. Barreras et al., “An Advanced Hardware-in-the-loop Simulation Battery Model for Battery Management Systemtesting,” IEEE Transactions on Industry Applications, 2016, to be published.
HVM CATAPULT: Energy Storage ConferenceInternational Digital Laboratory
24th Sep. 2015
BMS testing in HIL simulator
(a) 32 cells voltages vs BMS measured max. and min. (b) Detailed view
Dynamic discharge
C. Fleischer, J. V. Barreras et al., “Development of software and strategies for Battery Management System testing onHIL simulator,” Proceedings of the 2016 Eleventh International Conference on Ecological Vehicles and RenewableEnergies (EVER). Monte-Carlo: IEEE Press, 2016.
HVM CATAPULT: Energy Storage ConferenceInternational Digital Laboratory
24th Sep. 2015
C. Fleischer, J. V. Barreras et al., “Development of software and strategies for Battery Management System testing onHIL simulator,” Proceedings of the 2016 Eleventh International Conference on Ecological Vehicles and RenewableEnergies (EVER). Monte-Carlo: IEEE Press, 2016.
BMS testing in HIL simulator
(a) 32S pack current and pack voltage in time
(b) Switch box contactor logic
(c) Experimental vs BMS measured cells temperatures
Overtemperature during dynamic discharge
HVM CATAPULT: Energy Storage ConferenceInternational Digital Laboratory
24th Sep. 2015
BMS testing in HIL simulator
(a) Cells voltages in time (b) Cells temperatures in time
External short circuit close to cell’s tabs
C. Fleischer, J. V. Barreras et al., “Development of software and strategies for Battery Management System testing onHIL simulator,” Proceedings of the 2016 Eleventh International Conference on Ecological Vehicles and RenewableEnergies (EVER). Monte-Carlo: IEEE Press, 2016.
HVM CATAPULT: Energy Storage ConferenceInternational Digital Laboratory
24th Sep. 2015
BMS testing in HIL simulator
(a) 32S pack current and pack voltage in time(b) Cells voltages and balancing currents
Charge process
C. Fleischer, J. V. Barreras et al., “Development of software and strategies for Battery Management System testing onHIL simulator,” Proceedings of the 2016 Eleventh International Conference on Ecological Vehicles and RenewableEnergies (EVER). Monte-Carlo: IEEE Press, 2016.
HVM CATAPULT: Energy Storage ConferenceInternational Digital Laboratory
24th Sep. 2015
BMS testing in HIL simulator
(b) Experimental vs BMS measured cellstemperatures in time
(a) 32S pack current and pack voltage in time
Charge process at low temperatures
C. Fleischer, J. V. Barreras et al., “Development of software and strategies for Battery Management System testing onHIL simulator,” Proceedings of the 2016 Eleventh International Conference on Ecological Vehicles and RenewableEnergies (EVER). Monte-Carlo: IEEE Press, 2016.
HVM CATAPULT: Energy Storage ConferenceInternational Digital Laboratory
24th Sep. 2015
BMS testing in HIL simulator
Critical zero volt mode.Higher series resistance for a single cell.
Model based fault insertion
C. Fleischer, J. V. Barreras et al., “Development of software and strategies for Battery Management System testing onHIL simulator,” Proceedings of the 2016 Eleventh International Conference on Ecological Vehicles and RenewableEnergies (EVER). Monte-Carlo: IEEE Press, 2016.
HVM CATAPULT: Energy Storage ConferenceInternational Digital Laboratory
24th Sep. 2015
Malfunction of chargerNoise in cell voltage measurement
(a) Pack current and pack voltage in time
(b) 32 cells voltages in time
BMS testing in HIL simulator
Model based fault insertion
C. Fleischer, J. V. Barreras et al., “Development of software and strategies for Battery Management System testing onHIL simulator,” Proceedings of the 2016 Eleventh International Conference on Ecological Vehicles and RenewableEnergies (EVER). Monte-Carlo: IEEE Press, 2016.
HVM CATAPULT: Energy Storage ConferenceInternational Digital Laboratory
24th Sep. 2015
Application case 2 – dSPACE HILS
Single particle model implemented on a dSPACE real-time target. See users.ox.ac.uk/~engs1053
Identified to major challenges related to real-time targetODE solvers:
• only fixed time-step
• no iterative methods allowed
ensure the solution within the sample time
HVM CATAPULT: Energy Storage ConferenceInternational Digital Laboratory
24th Sep. 2015
Conclusions
More demanding battery applications, e.g. xEVs, requiremore advanced BMSs. In turn, more advanced BMSs
demand more complex and customized testing at all stagesof development
Tests on a HIL simulator can offer in comparison with teston real batteries key advantages in terms of cost, testing
times, flexibility, traceability, ease to reproduce or safety, inparticular beyond the normal range of operation, at earlystages of development or under fault insertion scenarios
HVM CATAPULT: Energy Storage ConferenceInternational Digital Laboratory
24th Sep. 2015
Acknowledgements
UK's innovation agency for supporting the project AMPLiFII(Automated Module-to-pack Pilot Line for Industrial Innovation)
Jorge V. Barreras, David A. HoweyDepartment of Engineering ScienceUniversity of Oxford
users.ox.ac.uk/~engs1053/
State-of-the-art of Hardware-in the-loop Solutions for BatteryManagement System Testing