Battery Management Controller Testing With Real-Time Battery Simulation
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Solution Overview
Problem
Current battery management systems face challenges in accurately estimating battery state and cycle life due to variable loads and differences in battery cells, requiring extensive manpower and time for testing, which increases costs and inefficiencies.
Innovation Solution
The development of test equipment and methods that include a battery-parameter recognition module, real-time simulation module, physical signal simulation module, and master equipment to automatically test battery management systems by calibrating sensors, generating battery models, and comparing simulated and estimated battery states, thereby reducing manual intervention and improving accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional manual testing methods are used for battery management systems, then testing accuracy can be maintained, but testing time and manpower requirements increase significantly
Solution Approach 1:
The patent creates a virtual battery management system model that replicates the functionality of the physical system. This virtual model allows automated testing without manual intervention, significantly reducing testing time while maintaining accuracy through precise simulation of battery behaviors and management logic.
Solution Approach 2:
The testing system performs self-validation through automated comparison of test results against expected outcomes. The system automatically generates test cases, executes them, and evaluates results without requiring continuous manual oversight, thereby reducing both time and manpower requirements while preserving testing accuracy.
2Measurement precision
If traditional manual testing methods are used for battery management systems, then detailed analysis can be performed, but labor costs and testing complexity increase
Solution Approach 1:
The patent replaces manual mechanical testing processes with an automated virtual simulation system. The virtual model computationally replicates battery management operations, eliminating the need for manual setup and execution while maintaining detailed analysis capabilities through software-based measurement and evaluation.
Solution Approach 2:
The system automatically adjusts and varies multiple battery operating parameters (temperature, charge rate, discharge rate, state of charge) within the virtual model to test different scenarios. This automated parameter variation enables comprehensive analysis without increasing manual complexity, as the software systematically explores the parameter space.
3Reliability
If extensive manual testing is performed to ensure battery management accuracy, then system reliability can be verified, but testing costs increase
Solution Approach 1:
By creating a faithful virtual replica of the battery management system, the patent enables comprehensive reliability testing without requiring proportional physical test resources. The virtual model can be instantiated multiple times and tested under various conditions without consuming additional physical batteries or manual testing resources.
Solution Approach 2:
The virtual battery management model serves multiple testing functions simultaneously - it can test different operating conditions, failure modes, and edge cases within a single unified platform. This multi-functionality reduces the total number of separate test setups and resources needed while maintaining thorough reliability verification.
Data Source
AI summary
Test equipment for a battery management system is provided. A battery-parameter recognition module measures a standard battery to obtain the first correction input, and uses the capacity test formula and the relaxation time test formula to perform a first charge and discharge test on the battery to be tested to obtain first battery parameter. A real-time simulation module determines the battery model and the simulated battery state based on the first battery parameter and the dynamic load. Each simulator of a physical signal simulation module provides a battery physical signal indicating the battery model. A connector provides the battery physical signal to the battery management controller under test. The battery management controller under test provides a stimulated battery state based on the battery physical signal. Master equipment compares the simulated battery state with an estimated battery state to determine whether the battery management controller under test is normal.