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Battery Management System (BMS) HiL Testing for Electric Vehicle

10/8/2024
Airbag

Project Introduction

In the electric vehicle sector, X-in-the-loop testing during development and validation phases has proven highly effective. This method uses real-time computing and physical data collection to simulate actual test targets, allowing evaluation of potential faults without the risks and costs of traditional testing. By replacing physical test targets, this approach reduces testing expenses, speeds up the design-to-integration process, and ensures thorough validation and significant cost efficiencies.   

 Our client has implemented hardware-in-the-loop (HiL) simulation testing for their electric vehicle battery management system. This system requires CAN FD communication for fast and reliable interactions between electronic control units and a data acquisition module to collect and record battery performance data. Initially, they used a simulation platform with real-time processors, PXI chassis, I/O, and CAN FD cards. However, with the growing popularity of electric vehicles and the integration of this application into end-of-line testing (EoL), the demand for equipment has surged. Consequently, the client is now evaluating more cost-effective alternatives. They are shifting towards industrial computer solutions paired with high-speed PCIe I/O cards, which have proven to be an economical and efficient solution for offline battery testing.

System Requirements

In this battery management system, various signals from the battery need to be acquired, including charge-discharge cycles, temperature, humidity, as well as CAN and other onboard communications. Through the simulation system, the real operating conditions of the battery can be effectively simulated.   

 The BMS HiL system is used for testing the control functions of EV battery management systems. It runs a complete vehicle model in real time to simulate various scenarios and connects to the BMS controller via an interface card. This setup effectively replicates the BMS's operating conditions.   

 The BMS controller includes two parts: the Battery Control Unit (BCU) and the Battery Monitoring Unit (BMU). In the BMS HiL system, a battery simulation device is used to emulate the vehicle battery pack, providing power to the BMU controller. Each battery cell can be independently controlled, facilitating battery balancing management.   

 The key components of the BMS HiL system include an Advantech hardware platform, a customized development software platform based on Advantech C code, and simulation models including real-time control systems and I/O drivers. This system operates by configuring and executing simulation models of battery, charging, and vehicle dynamics on the host computer. Through the simulation models, relevant signals during battery operation are outputted or collected, and data exchange between the HiL device and controllers is facilitated via CAN FD network communication on the ECU/BCU. The main station completes functional testing of BMS system nodes. Testing equipment includes a test bench (integrated testing hardware platform), BMS signal test interfaces, and simulation models.

Project Implementation

  • ACP-4340 : 4U Rackmount Chassis for Full-size SHB/SBC or ATX/MicroATX Motherboard with 4 Hot Swap Drive Trays
  • PCE-5133: LGA1700 R680E Full size SBC
  • PCE-5B13-03: 13 Slots PICMG 1.3 BP, 9 PCIe,3 PCI
  • PCIE-1753-AE: 96-ch Digital I/O PCIE Card
  • PCIE-1682F-AE: 2-Port CANFD-Bus PCIE w/ Isolation
  • PCIE-1805-AE: 1MS/s, 16-bit, 32-ch Analog Input PCIE Card
  • PCI-1747U-AE: 250 kS/s, 16-bit, 64-ch Analog Input Universal PCI Card
  • PCI-1780U-AE: 8-ch, 16-bit Counter/Timer Universal PCI Card
  • DAQNavi: Data acquisition software to enable edge intelligence for DAQ devices
  • Linux RTOS: Co-work with 3rd party software vendor

System Description

The client selected Advantech's ACP-4340 4U rackmount chassis paired with a full-sized SBC PCE-5133 based on 12th Gen. Intel® Core™ processors. Combined with the PCE-5B13-03 13-slot backplane, this IPC system supports up to 12 DAQ (Data Acquisition) cards. It can be customized to meet industry-specific needs. For instance, in a BMS application, this system integrates PC-based controllers with multiple I/O cards to handle measurement and control signals necessary for simulating real-world scenarios such as charging, discharging, capacity testing, and battery cell lifecycle management.   

 In addition to battery usage simulations utilizing industrial PCs and DAQ/CANFD cards, Advantech enhances its capabilities through strategic partnerships with third-party software developers. This collaboration has enabled the implementation of a real-time system on an embedded platform with Linux RTOS.   

 Advantech's DAQNavi offers customized services to meet the specific algorithm and control component needs of clients. This includes tailored example programs verified for efficient operation on Linux RTOS. This integration significantly eases the transition for clients moving from traditional PXI chassis with RTOS to Advantech's more efficient, tailored solution.

System Diagram

System Diagram

Conclusion

Real-time simulation systems are increasingly vital in electric vehicle industry. This demand has led to more system integrators and software partners entering the field. Advancements in multi-core CPUs now allow these real-time controls to be effectively implemented on Industrial PCs, reducing costs by 50-60%.   

 Advantech distinguishes itself in this market with its comprehensive solutions for data acquisition (PCI/PCIE DAQ) and vehicle communication (CAN/CANFD). These are essential for measurement and control in these industries. Moreover, Advantech's extensive network of software partners enables the development of tailored industry-specific software.   

 In addition to hardware, Advantech offers custom example programs to speed up client development, making them an attractive partner for businesses looking to move beyond traditional PXI systems. This approach opens new avenues for business expansion in industrial applications.