Integrated BMS hardware-in-the-loop test platform and test method thereof

Abstract

The invention discloses an integrated BMS hardware-in-the-loop test platform. A real-time processor, various board cards connected with the real-time processor, an upper computer provided with VeriStand software, a battery module and the like are integrated. The invention further discloses a testing method of the integrated BMS hardware-in-the-loop testing platform. The system can accurately simulate the working states of the battery system, including the output and collection of various analog signals such as voltage, current, resistance, temperature and the like, and simulate the voltage change, resistance change, insulation resistance conditions and even high-voltage signals of the battery pack, so that the BMS can be tested in a laboratory environment as in a real vehicle environment. The research and development and test level of the BMS can be remarkably improved, and the product development period can be shortened.

Description

TECHNICAL FIELD

[0001] The present application relates to BMS testing technology, in particular to an integrated BMS hardware-in-the-loop test platform and its testing method. BACKGROUND

[0002] HIL (Hardware-in-the-Loop) is a technology part used for testing and verifying systems. It simulates the operating environment of the system and combines the software part of the system with the actual hardware part for testing.

[0003] BMS-HIL testing project aims to use hardware-in-the-loop (HIL) testing technology to conduct comprehensive and repeatable functional and performance tests on battery management system (BMS). By simulating real batteries and vehicle electrical systems, this test environment can verify the working conditions of BMS under various working conditions, improving the reliability and stability of the system.

[0004] Currently, the existing HIL system has the following shortcomings:

[0005] 1. The HIL system is usually composed of multiple different hardware components, and the configuration and integration of these components may involve complex engineering tasks and technical challenges;

[0006] 2. Since the system simulates the behavior of the actual system through simulation and emulation technology, there are certain model and precision limitations;

[0007] 3. Although existing technologies can simulate a variety of operating conditions and fault conditions, it is still difficult to cover all possible test scenarios. Some special cases and boundary conditions may not be fully verified by the HIL system. SUMMARY

[0008] In order to solve the above problems of the prior art, the present application provides an integrated BMS hardware-in-the-loop test platform and its testing method, which can significantly improve the research and development and testing level of BMS, and help to shorten the product development cycle.

[0009] In one aspect, a BMS hardware under test includes:

[0010] A host computer installed with VeriStand software and connected with a battery simulator;

[0011] A real-time processor connected with the host computer and connected with various types of board cards, running a real-time operating system, and performing model calculation, data processing and real-time control;

[0012] A high-voltage relay board card connected with the BMS hardware, simulating the switching action of the high-voltage system, controlling the on-off of the actual or virtual high-voltage input to the BMS, verifying the control logic of the BMS for the connection and disconnection of the high-voltage, and the relay control signal being sent by the real-time processor;

[0013] A CAN communication board card connected with the BMS hardware, simulating the CAN bus communication between the BMS and the battery pack and other vehicle components in the real vehicle environment, sending and receiving CAN messages to realize the data interaction between the BMS and the simulated battery system;

[0014] An analog input / output board card connected with the battery simulator or the real battery system through an analog signal line, simulating the battery voltage output and collecting the battery voltage feedback;

[0015] A digital input / output board card connected with the battery simulator, sending and receiving digital signals, controlling the actuator or reading the digital signal state of the BMS;

[0016] A battery pack voltage simulation board card connected with the BMS hardware, precisely simulating the voltage change of each single battery in the battery pack, ensuring that the voltage balancing strategy of the BMS under various working conditions can be verified.

[0017] A resistance simulation board card connected with the BMS hardware, simulating the internal resistance of the battery pack and the external load resistance, testing whether the BMS can correctly estimate the SOC, SOP and SOH parameters under different resistance conditions;

[0018] An insulation resistance simulation board card connected with the BMS hardware, simulating the change of the insulation resistance of the battery pack;

[0019] A battery module for overall power supply of the test platform.

[0020] Further comprising an insulation monitoring module connected with the BMS hardware and connected with the real-time processor for real-time monitoring of the change of the insulation resistance of the simulated battery pack, ensuring that the BMS can respond in time in the case of insulation failure.

[0021] Further comprising a fault injection unit including an actuator fault injection board and a single battery fault injection board, connected with the real-time processor and receiving instructions from the real-time processor, for artificially creating various fault states to test the diagnosis and protection functions of the BMS under abnormal conditions.

[0022] In another aspect, a test method of an integrated BMS hardware-in-the-loop test platform includes the following steps:

[0023] The real-time processor is connected with an upper computer installed with VeriStand software, and is connected with various boards, runs a real-time operating system, and performs model calculation, data processing and real-time control;

[0024] The high-voltage relay board is connected with the BMS hardware, simulates the switching action of the high-voltage system, controls the on-off of the actual or virtual high-voltage input to the BMS, and verifies the control logic of the BMS for the on-off of the high voltage, wherein the relay control signal is sent by the real-time processor;

[0025] The CAN communication board is connected with the BMS hardware, simulates the CAN bus communication between the BMS and the battery pack and other vehicle components in a real vehicle environment, sends and receives CAN messages to realize the data interaction between the BMS and the simulated battery system;

[0026] The battery simulator or the real battery system connected with the upper computer through the analog input / output board and the analog signal line is used to simulate the battery voltage output and collect the battery voltage feedback;

[0027] The battery simulator is connected with the digital input / output board to send and receive digital signals, control actuators or read the digital signal state of the BMS;

[0028] The battery pack voltage simulation board is connected with the BMS hardware to accurately simulate the voltage change of each single battery in the battery pack, and ensure that the voltage balancing strategy of the BMS under various working conditions is verified.

[0029] The resistance simulation board is connected with the BMS hardware to simulate the internal resistance of the battery pack and the external load resistance, and test whether the BMS can correctly estimate the SOC, SOP and SOH parameters under different resistance conditions;

[0030] The insulation resistance simulation board is connected with the BMS hardware to simulate the change of the insulation resistance of the battery pack;

[0031] The battery module is used to supply power to the test platform as a whole.

[0032] The insulation monitoring module is connected with the BMS hardware and the real-time processor to monitor the change of the insulation resistance of the simulated battery pack in real time, and ensure that the BMS can respond in time in the case of insulation failure.

[0033] The fault injection unit including the actuator fault injection board and the single battery fault injection board is connected with the real-time processor and receives instructions from the real-time processor to artificially create various fault states to test the diagnosis and protection functions of the BMS under abnormal conditions.

[0034] The integrated BMS hardware-in-the-loop test platform and its test method have the following advantages:

[0035] 1. High simulation: It can accurately simulate the working state of the battery system, including the output and collection of various analog signals such as voltage, current, resistance, temperature, and the simulation of voltage changes, resistance changes, insulation resistance conditions, and even high-voltage signals, so that the BMS can be tested in the laboratory environment as in the real vehicle environment.

[0036] 2. Comprehensive testing capability: It provides fault injection function, which can simulate battery cell faults, actuator faults and other common and irregular fault states to fully verify the response ability and protection mechanism of BMS when facing different fault conditions.

[0037] 3. Real-time interaction and control: Real-time communication with BMS is realized through real-time processors and CAN communication board cards to accurately simulate the CAN bus communication environment, ensuring the correct execution of BMS control instructions and real-time acquisition of state feedback.

[0038] 4. Safety guarantee: Through high-voltage simulation board cards and high-voltage relay board cards, safe and reliable isolation and control are realized while simulating high-voltage signals, effectively preventing potential risks.

[0039] 5. Precision and efficiency: The simulation output and input board cards have high-precision AD / DA conversion capability and high-speed data acquisition and update rate, greatly improving the precision and efficiency of the test.

[0040] 6. Flexibility and scalability: Hardware resources such as simulation channel number and fault injection channel number can be flexibly configured according to test requirements, and sufficient communication interfaces and expansion slots are reserved to meet the testing needs of BMS of different scales and complexities.

[0041] 7. Automation and standardization: With the help of software platforms such as VeriStand, test sequences can be automatically executed, data can be recorded and analyzed, greatly simplifying the test process and improving the consistency and reliability of the test.

[0042] 8. It can significantly improve the R&D and testing level of BMS, and help shorten the product development cycle BRIEF DESCRIPTION OF DRAWINGS

[0043] Figure 1 is the principle diagram of the in-the-loop test platform of the present application. DETAILED DESCRIPTION

[0044] The integrated BMS hardware-in-the-loop test platform and its test method will be further described as follows: Figure 1As shown, the integrated BMS hardware-in-loop test platform of the application includes the BMS hardware to be tested, a host computer, a battery simulator, a real-time processor, a high-voltage relay board card, a CAN communication board card, an analog input / output board card, a digital input / output board card, a battery pack voltage simulation board card, an insulation resistance simulation board card, a battery module, an insulation monitoring module, a fault injection unit, etc. The above hardware of the loop test platform can be connected through a PXI or PXIe backplane bus in the BMS hardware-in-loop (HIL) test bench to form an overall closed-loop control system. The specific connection relationship is as follows:

[0045] The real-time processor (such as the real-time CPU board in the PXIe-8861 or PXIe-1084 chassis) serves as the central processing unit of the entire system and exchanges high-speed data with other board cards through the PXI bus.

[0046] The CAN communication board card (such as PXI-8510 / 6) is inserted into the PXI chassis where the real-time processor is located, connected through the bus, simulates the CAN network communication in the real world, and communicates with the BMS to be tested in both directions.

[0047] The analog input / output board card (such as TB2710 / TB2720) is connected to the real-time processor, simulates the battery voltage output and collects the battery voltage feedback, and is connected to the battery simulator or the real battery system through an analog signal line.

[0048] The digital input / output board card (such as TB2810 / TB2820) is also connected to the real-time processor through the PXI bus, used to send and receive digital signals, control actuators or read the digital signal state of the BMS.

[0049] The battery pack voltage simulation board card (such as TB9142) is used to simulate the voltage of single battery cells, and multiple board cards can be cascaded to simulate larger battery packs. The output is connected to the voltage sampling interface of the BMS through appropriate signal lines.

[0050] The fault injection unit (including an actuator fault injection board and a single battery fault injection board) receives instructions from the real-time processor through a digital interface (such as RS232 or RS485) to simulate fault conditions.

[0051] The high-voltage simulation board card (such as TB9112) provides a high-voltage small-current signal output, which can be connected to the BMS high-voltage signal interface through an isolation and protection circuit.

[0052] The high-voltage relay board card (such as TB9114) is used to control the on-off of the actual high-voltage input to the BMS, and the relay control signal is sent by the real-time processor.

[0053] Resistor emulation board (e.g., TB9107) simulates internal or external resistance of the battery and connects to the BMS current monitoring section.

[0054] Insulation resistance emulation board (e.g., TB9105) and insulation monitoring module (e.g., TB9108) interact with the real-time processor through LVDS high-speed communication links or other communication interfaces, respectively, and are connected to the BMS insulation monitoring loop.

[0055] Low-voltage programmable power supply and power switching board (e.g., TB6202) provides stable power supply for the entire test system and controls and feeds back to the real-time processor through digital output channels and analog signal lines.

[0056] Battery simulator (simulates the real battery behavior) connects to the analog input board card and digital input / output board card through the analog signal interface, and communicates with the host computer software (e.g., VeriStand) through CAN communication.

[0057] Its working principle mainly revolves around simulating the real behavior of the battery system and interacting with the BMS in real time to verify and test the functions of the BMS. The following is a detailed description of its working principle:

[0058] Real-time processor (e.g., PXIe-8861): as the core controller, it runs a real-time operating system and undertakes the tasks of model calculation, data processing and real-time control. It is connected to various board cards through the PXIe bus and responds to the control commands and state feedback of the BMS in real time.

[0059] CAN communication board card (e.g., PXI-8510 / 6): simulates the CAN bus communication between the BMS and the battery pack and other vehicle components in the real automotive environment. Through this board card, CAN messages can be sent and received, realizing data interaction between the BMS and the simulated battery system.

[0060] Analog output board card (e.g., TB2710): generates analog voltage signals to simulate the changes of single battery voltage, temperature and other analog signals, which represent different working states of the battery pack and are transmitted to the BMS for real-time monitoring and control.

[0061] Analog input board card (e.g., TB2720): collects analog signals such as current and voltage from the battery simulator or other real sensors and converts these analog signals into digital signals for data analysis by the real-time processor.

[0062] Digital input / output board card (e.g., TB2810 / TB2820): controls and monitors digital signals such as switch status, fault flags, etc., realizes digital interface communication with the BMS, simulates the response of actuators and receives control instructions from the BMS.

[0063] Battery voltage simulation board (e.g. TB9142): Accurately simulate the voltage changes of individual cells in the battery pack, ensuring that the BMS's voltage balancing strategy is verified under various operating conditions.

[0064] Fault injection unit: By executing actuator fault injection boards and cell fault injection boards, various fault states are artificially created to test the BMS's diagnosis and protection functions under abnormal conditions.

[0065] High-voltage simulation board (e.g. TB9112): Simulate high-voltage signals in new energy vehicles to help verify the safety and reliability of the BMS in high-voltage signal processing.

[0066] High-voltage relay board (e.g. TB9114): Simulate the switching action of the high-voltage system to control the on-off of actual or virtual high-voltage circuits, verifying the BMS's control logic for high-voltage connection and disconnection.

[0067] Resistance simulation board (e.g. TB9107): Simulate the internal resistance of the battery pack and external load resistance to test whether the BMS can correctly estimate parameters such as SOC, SOP, and SOH under different resistance conditions.

[0068] Insulation resistance simulation board (e.g. TB9105) and insulation monitoring module (e.g. TB9108): Simulate changes in the insulation resistance of the battery pack and monitor it in real time to ensure that the BMS can respond in a timely manner in the event of insulation failure.

[0069] Low-voltage program-controlled power supply: Provide stable and programmable low-voltage power for the test system to simulate the power supply of other low-voltage electrical systems in vehicles.

[0070] Through the coordinated work of the above hardware, the test platform can simulate various actual application scenarios and fault conditions, allowing the BMS to undergo rigorous testing in a safe experimental environment, verifying its functional correctness, performance stability, and safety. At the same time, through software platforms such as VeriStand, the test process can be monitored and data analyzed throughout.

[0071] In summary, the present application significantly improves the research and development and testing level of BMS, helps to shorten the product development cycle, reduce the cost of real vehicle testing, and improve the quality and safety of products, and has an important promoting effect on the research and development of battery management systems in the new energy vehicle industry.

[0072] However, those skilled in the art in the technical field should realize that the above embodiments are only used to illustrate the present application, and are not used as a limitation on the present application, as long as the changes and modifications of the above described embodiments are within the spirit and scope of the present application, they will fall within the scope of the claims of the present application.

Claims

1. An integrated BMS hardware-in-the-loop test platform, comprising the BMS hardware under test, characterized in that, Also includes: The host computer has VeriStand software installed and is connected to a battery simulator; The real-time processor is connected to the host computer and to the following types of boards. It runs a real-time operating system and performs model calculations, data processing, and real-time control. The high-voltage relay board is connected to the BMS hardware to simulate the switching action of the high-voltage system and control the on / off of the actual or virtual high-voltage input to the BMS. It is used to verify the control logic of the BMS for high-voltage connection and disconnection. Its relay control signal is issued by the real-time processor. The CAN communication board is connected to the BMS hardware to simulate the CAN bus communication between the BMS and the battery pack and other vehicle components in a real automotive environment. It simulates sending and receiving CAN messages to realize data interaction between the BMS and the simulated battery system. Analog input / output board, which interfaces with battery simulator or real battery system through analog signal lines, to simulate battery voltage output and collect battery voltage feedback; Digital input / output board, connected to the battery simulator, is used to send and receive digital signals, control actuators, or read the digital signal status of the BMS; The battery pack voltage simulation board is connected to the BMS hardware to accurately simulate the voltage changes of each individual cell in the battery pack, ensuring that the voltage balancing strategy of the BMS under various operating conditions can be verified. The resistance simulation board is connected to the BMS hardware to simulate the internal resistance of the battery pack and the external load resistance, and to test whether the BMS can correctly estimate parameters such as SOC, SOP and SOH under different resistance conditions. The insulation resistance simulation board is connected to the BMS hardware and is used to simulate the changes in the insulation resistance of the battery pack. The battery module is used to provide overall power to the test platform.

2. The integrated BMS hardware-in-the-loop test platform as described in claim 1, characterized in that, Also includes: The insulation monitoring module is connected to the BMS hardware and interacts with the real-time processor to monitor changes in the insulation resistance of the simulated battery pack in real time, ensuring that the BMS can respond promptly in the event of insulation failure.

3. The integrated BMS hardware-in-the-loop test platform as described in claim 1, characterized in that, Also includes: The fault injection unit, including the actuator fault injection board and the single-cell battery fault injection board, is connected to the real-time processor and receives instructions from the real-time processor to artificially create various fault states in order to test the diagnostic and protection functions of the BMS under abnormal conditions.

4. The testing method for an integrated BMS hardware-in-the-loop test platform as described in claim 1, characterized in that, Includes the following steps: The system connects to a host computer with VeriStand software installed via a real-time processor, and is connected to the following types of boards to run a real-time operating system and perform model calculations, data processing, and real-time control. The high-voltage relay board is connected to the BMS hardware to simulate the switching action of the high-voltage system and control the on / off of the actual or virtual high-voltage input to the BMS. This is used to verify the control logic of the BMS for high-voltage connection and disconnection. The relay control signal is issued by the real-time processor. The CAN communication board is connected to the BMS hardware to simulate the CAN bus communication between the BMS and the battery pack and other vehicle components in a real automotive environment. By simulating the sending and receiving of CAN messages, the data interaction between the BMS and the simulated battery system is realized. It uses an analog input / output board and connects to a host computer via analog signal lines to interface with a battery simulator or a real battery system to simulate battery voltage output and collect battery voltage feedback. It connects to the battery simulator via a digital input / output board to send and receive digital signals, control actuators, or read the digital signal status of the BMS; The battery pack voltage simulation board is connected to the BMS hardware to accurately simulate the voltage changes of each individual cell in the battery pack, ensuring that the voltage balancing strategy of the BMS under various operating conditions can be verified. The resistance simulation board is connected to the BMS hardware to simulate the internal resistance of the battery pack and the external load resistance, and to test whether the BMS can correctly estimate parameters such as SOC, SOP and SOH under different resistance conditions. The insulation resistance simulation board is connected to the BMS hardware to simulate the changes in the insulation resistance of the battery pack. The battery module is used to provide overall power to the test platform.

5. The testing method for an integrated BMS hardware-in-the-loop test platform as described in claim 4, characterized in that, It also includes the following steps: The insulation monitoring module is connected to the BMS hardware and interacts with the real-time processor to monitor changes in the insulation resistance of the simulated battery pack in real time, ensuring that the BMS can respond promptly in the event of insulation failure.

6. The testing method for an integrated BMS hardware-in-the-loop test platform as described in claim 4, characterized in that, It also includes the following steps: The fault injection unit, which includes an actuator fault injection board and a single cell fault injection board, is connected to the real-time processor and receives instructions from the real-time processor to artificially create various fault states in order to test the diagnostic and protection functions of the BMS under abnormal conditions.

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