Apparatus and method for testing function and safety of BMS based on dynamic simulation

Abstract

The present invention relates to a dynamic simulation-based BMS functional safety test device capable of evaluating the functional safety of a BMS by precisely reflecting various actual usage conditions such as actual driving environments, temperature changes, aging, and impacts. The device comprises: a battery simulation module that operates like an actual battery and variably controls voltage, current, and temperature at the battery cell, module, and pack levels input to the BMS, and simulates abnormal conditions such as short circuits, cell defects, and changes in internal resistance occurring within the battery; an environment simulation module that simulates changes in external environmental factors such as temperature, vibration, humidity, and pressure affecting the battery state in the actual usage environment of the battery; and a data analysis module that analyzes response data of the battery management system in real time. The data analysis module includes a data collection and processing unit that collects voltage, current, temperature, SOC (State of Charge), SOH (State of Health), charge / discharge status, and error code data output from the BMS, and stores them together with the input conditions of the battery simulation module and the environment simulation module. It may include a data analysis and verification unit that compares the collected and processed data with normal data patterns to detect whether there is an operational abnormality of the BMS, and analyzes whether the BMS responded correctly if an operational abnormality is detected.

Description

Technology Field

[0001] The present invention relates to a test device and method for verifying the functional safety of a battery management system (BMS), and more particularly to a technology for evaluating the performance of a BMS by dynamically simulating the operation of a battery system used in electric vehicles (EVs), energy storage systems (ESS), etc. Background Technology

[0002] Existing BMS test devices simulate the static environment of a battery pack, which has limitations in that they cannot adequately reflect dynamic environmental changes that may occur under actual usage conditions. For example, while static tests such as voltage, current, and temperature are possible, factors such as impacts during driving, sudden temperature changes, and regenerative braking cannot be sufficiently simulated. Consequently, it is difficult to reliably evaluate the performance of the BMS in real-world driving environments. Prior art literature

[0003] Published Patent Application 10-2013-0066283 (June 20, 2013) The problem to be solved

[0004] The technical problem that the present invention aims to solve is to provide a dynamic simulation-based BMS functional safety test device capable of evaluating the functional safety of a BMS by precisely reflecting various actual usage conditions such as actual driving environments, temperature changes, aging, and impact. means of solving the problem

[0005] The present invention, for solving the aforementioned technical problem, is a test device for evaluating the functional safety of a battery management system (BMS), comprising: a battery simulation module that operates like an actual battery and variably controls voltage, current, and temperature at the battery cell, module, and pack levels input to the BMS, and simulates abnormal conditions such as short circuits, cell defects, and changes in internal resistance occurring within the battery; an environment simulation module that simulates changes in external environmental factors such as temperature, vibration, humidity, and pressure that affect the battery condition in an actual usage environment; and a data analysis module that analyzes response data of the battery management system in real time.

[0006] The above data analysis module may include: a data collection and processing unit that collects voltage, current, temperature, SOC (State of Charge), SOH (State of Health), charge / discharge status, and error code data output from the BMS and stores them together with the input conditions of the battery simulation module and the environment simulation module; and a data analysis and verification unit that compares the collected and processed data with normal data patterns to detect whether there is an operational abnormality of the BMS, and analyzes whether the BMS responded correctly when an operational abnormality is detected. Effects of the invention

[0007] According to the present invention, the problem of existing BMS test devices failing to reflect the actual usage environment is resolved, and the functional safety of the BMS can be evaluated more precisely by providing real-time dynamic simulation and AI-based analysis functions. Brief explanation of the drawing

[0008] FIG. 1 is a block diagram showing the main configuration of a BMS functional safety test device according to an embodiment of the present invention. Specific details for implementing the invention

[0009] In order to provide a detailed explanation sufficient for a person skilled in the art to easily implement the technical concept of the present invention, the most preferred embodiment of the present invention will be described with reference to the accompanying drawings. It should be noted that in assigning reference numerals to the components of each drawing, the same components are given the same reference numeral whenever possible, even if they are shown in different drawings. Furthermore, in describing the present invention, if it is determined that a detailed description of related known components or functions could obscure the essence of the present invention, such detailed description is omitted.

[0010] Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings attached to this specification.

[0011] FIG. 1 is a block diagram showing the main configuration of a BMS functional safety test device according to an embodiment of the present invention.

[0012] Referring to FIG. 1, the BMS functional safety test device may include a battery simulation module (110), an environment simulation module (120), a data analysis module (130), a cloud integration module (140), and an interface module (150).

[0013] The battery simulation module (110) is connected to at least one input port of the BMS and controls the voltage, current, and temperature at the battery cell, module, and pack levels for BMS operation testing, and provides them to the BMS, and can simulate abnormal conditions such as short circuits, cell defects, and changes in internal resistance occurring within the battery. To this end, the battery simulation module (110) may be equipped with a programmable power supply capable of precisely controlling individual cell voltages, an electronic load that variably adjusts the load during dustproofing, and a temperature control system that simulates a thermal environment by controlling the cell temperature.

[0014] Additionally, the battery simulation module (110) can be designed to enable simulation of multi-channel cells. For example, a multi-cell voltage generation and control circuit is provided to support a 96S - 400V battery pack that is actually installed, and can be implemented to enable current flow control, balancing circuit, and individual cell resistance setting for charge / discharge simulation.

[0015] Specifically, individual cell voltage regulation uses a DAC (Digital-to-Analog Converter) based voltage generation circuit, and the cell voltage can be adjusted using a MOSFET or a linear regulator. The voltage range is 3.0V to 4.2V based on lithium-ion cells, and when connected in series, it can support 96S = a maximum of 403V (4.2V * 96).

[0016] The discharge current per cell can be controlled using an electronic load circuit as a circuit to regulate the current flow for each cell, and a charging simulation can be performed to increase the cell voltage using a current source.

[0017] Since the BMS detects imbalance between cells and performs balancing operations, to test this, imbalance can be intentionally created by adjusting the equivalent series resistance of each cell through a resistance network and MOSFET-based load control.

[0018] The environment simulation module (120) can simulate changes in external environmental factors such as temperature, vibration, humidity, and pressure that affect the battery's condition in the actual usage environment of the battery. In other words, it performs the role of virtually creating external factors that occur in the actual environment and affecting the battery's condition.

[0019] Temperature environment simulation allows for the establishment of scenarios such as cooling system malfunctions or sudden spikes in ambient temperature, enabling testing of whether the BMS performs protection functions in response to temperature changes. Additionally, vibration and shock simulations can reflect vibrations or shocks occurring during road driving to alter battery cell connection conditions, such as connector failures. Furthermore, additional simulations may be included, such as humidity and moisture intrusion simulations capable of detecting changes in insulation resistance when moisture penetrates energy storage systems (ESS) or electric vehicles, and pressure and altitude change simulations that simulate changes in internal battery gas pressure during operation in aircraft or high-altitude regions.

[0020] The battery simulation module (110) and the environment simulation module (120) can operate individually, but can be operated in conjunction with each other for more precise testing.

[0021] For example, for a high-temperature charging test, if the environment simulation module sets the temperature to 50°C and the battery simulation module supplies a normal charging voltage (4.2V), it is possible to verify whether the BMS limits charging under high-temperature conditions. Additionally, in a battery cell failure test caused by vibration, if the environment simulator simulates a severe vibration environment (e.g., road impact while driving) and the battery simulator applies a specific cell voltage failure (below 2.5V), it is possible to verify whether the BMS detects this and outputs a warning. Furthermore, as a battery internal short-circuit test due to pressure changes, if the environment simulator applies a change in altitude (e.g., an airplane takeoff scenario) and the battery simulator simulates a short-circuit condition (e.g., a sudden voltage drop), it is possible to verify whether the BMS detects this and performs discharge cutoff.

[0022] The data analysis module (130) collects and analyzes response data of the battery management system in real time and performs the function of detecting anomalies and providing feedback on the results. The data analysis module (130) may include a data collection and processing unit, an AI-based anomaly detection unit, and a log data analysis and automatic report generation unit.

[0023] The data collection and processing unit can collect voltage, current, temperature, SOC (State of Charge), SOH (State of Health), charge / discharge status, and error code data output from the BMS, and store them together with the input conditions of the battery simulation module and the environment simulation module. In addition, sensor data, system logs, error codes (DTC, Diagnostic Trouble Codes), etc. generated by the BMS can be collected in real time via CAN / LIN communication.

[0024] The AI-based anomaly detection unit utilizes machine learning models to detect abnormal battery operation and can automatically detect patterns deviating from normal ranges by comparing them with historical data. Additionally, if signs of anomaly are detected, it can verify whether the BMS's protection functions operated properly.

[0025] After the test is completed, the log data analysis unit analyzes whether the BMS's response and protection operations were performed normally and identifies problems through data visualization (graphs, heatmaps, etc.). Additionally, it can generate an automatic evaluation report based on the test results.

[0026] Example (1): Test of BMS overvoltage protection function

[0027] The BMS functional safety test device can verify whether the BMS performs charging cutoff when the battery cell voltage is 4.3V or higher.

[0028] (Testing process)

[0029] 1) The battery simulation module sets a specific cell voltage to 4.3V

[0030] 2) Observe whether the BMS performs charge cutoff.

[0031] 3) The data analysis module analyzes the BMS log to check if a charging cutoff signal has occurred.

[0032] 4) If the BMS did not cut off charging, anomaly detection and error report generation

[0033] (Result Analysis)

[0034] - Normal: BMS sends charging cutoff signal at 4.3V -> Test passed

[0035] - Anomaly: BMS does not send charging cutoff signal -> Dangerous state -> Generate protection function error report

[0036] Example (2): BMS response test to rapid temperature change

[0037] The BMS functional safety test device can verify whether the BMS performs charging limiting when the battery temperature is 60°C or higher.

[0038] (Testing process)

[0039] 1) The environment simulation module simulates the battery temperature at 60°C.

[0040] 2) Verify that the BMS performs charging limits.

[0041] 3) Analyze whether the data analysis module detects a charging limit signal in the BMS log.

[0042] 4) If the BMS fails to perform charging limits, the AI ​​detects an anomaly and generates a warning report.

[0043] (Result Analysis)

[0044] - Normal: BMS limits charging at 60°C -> Passed test

[0045] - Anomaly: BMS does not perform charge limiting -> Protection function error occurs

[0046] Example (3): Battery connector defect detection test in a vibration environment

[0047] The BMS functional safety test device can verify whether the BMS detects a battery connector defect when strong vibrations occur.

[0048] (Testing process)

[0049] 1) The environment simulation module applies strong vibrations to temporarily disconnect the battery connector.

[0050] 2) Check if the BMS checks the battery connection status and sends an abnormality detection signal.

[0051] 3) The data analysis module analyzes the BMS logs to check for the occurrence of error codes.

[0052] 4) When an anomaly is detected, analyze the BMS's response logic and evaluate whether the protection operation is normal.

[0053] (Result Analysis)

[0054] - Normal: BMS outputs error code after detecting battery short circuit -> Test passed

[0055] - Anomaly: BMS fails to detect error -> Protection function error -> Report generated

[0056] Optimal embodiments have been disclosed in the drawings and specification as described above. Specific terms have been used herein, but they are used only for the purpose of describing the invention and are not intended to limit the meaning or the scope of the invention as described in the claims. Therefore, those skilled in the art will understand that various modifications and equivalent alternative embodiments are possible therefrom. Accordingly, the true technical scope of protection of the invention should be determined by the technical spirit of the appended claims. Explanation of the symbols

[0057] 110: Battery Simulation Module 120: Environment Simulation Module 130: Data Analysis Module 140 : Cloud Integration Module 150 : Interface Module

Claims

Claim 1 A test device for evaluating the functional safety of a battery management system (BMS) comprises: a battery simulation module that operates like a real battery and variably controls voltage, current, and temperature at the battery cell, module, and pack levels input to the BMS, and simulates abnormal conditions such as short circuits, cell defects, and changes in internal resistance occurring within the battery; an environment simulation module that simulates changes in external environmental factors such as temperature, vibration, humidity, and pressure affecting the battery condition in a real-world usage environment; and a data analysis module that analyzes response data of the battery management system in real time. The data analysis module comprises: a data collection and processing unit that collects voltage, current, temperature, SOC (State of Charge), SOH (State of Health), charge / discharge status, and error code data output from the BMS and stores them together with the input conditions of the battery simulation module and the environment simulation module; and a data analysis and verification unit that compares the collected and processed data with normal data patterns to detect whether there is an operational abnormality of the BMS, and if an operational abnormality is detected, analyzes whether the BMS responded correctly.

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