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Ensuring the optimum performance of a battery management system (BMS) requires measuring the performance of cell, module, and pack voltage, current, and temperature, plus verification of the operational performance of the battery and the cell supervisory circuits (CSCs), which includes static and dynamic accuracy measurements of temperature sensors and Hall-effect sensors at the cell, module, and pack levels. The test setup traditionally requires a known-good set of cells, modules, and packs operating in a controlled environment to test under different environmental conditions. This environment can be hazardous when engineers perform safety tests that bring cells close to their operating limits. In addition, each test requires returning the cells to the known-good condition before the next test can begin.
Testing a BMS efficiently and safely requires emulating cells connected in series and parallel, and emulating their behavior based on temperature and environmental variations. Engineers need a BMS environment with emulators to simulate the cells, current, temperature sensors, and insulation resistance. The system needs to estimate the state of charge (SOC) and state of health (SOH) of the battery and emulate the variables that change during the charging process. Additional interfaces are required to test monitoring systems and communication with other components, such as the electronic control unit (ECU). Closed-loop emulation of the different components enables the verification of all functions, routines, and algorithms to validate BMS functionality, safety, and performance.
Additional resources for battery management system testing
Testing high-power electric vehicle (EV) battery packs requires emulation of its operating environment. Learn how to use analysis, emulation, and electrochemical impedance spectroscopy to ensure optimal real-world performance of high-power EV battery packs.
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Validating electric vehicle (EV) battery modules requires testing each battery cell and module connection. Learn how to set up a test to emulate your module's source and sink, verify its performance in real-world scenarios, and measure its main electrochemical parameters.
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Testing electric vehicle (EV) battery cells requires characterization and then optimization of a battery cell's chemistry and material. Learn how to use analysis and electrochemical impedance spectroscopy measurements to detect potential cell weakness or deterioration.
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