Battery Emulation Device With Galvanic Isolation And Fault Simulation
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Solution Overview
Problem
Current battery simulation systems are unable to simulate faults such as cable ruptures due to high voltages and additional measurement lines, which preclude the use of failure simulation cards typically used in HIL simulations.
Innovation Solution
A battery emulation device with a control unit and emulation channels that include voltage sources, amplifier units, connection lines, measurement lines, and fault simulation devices to simulate fault states, allowing for the simulation of cable ruptures and other faults while maintaining galvanic isolation and high precision voltage control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high voltage battery simulation is implemented with galvanic isolation and measurement lines, then safety and measurement precision are improved, but the ability to simulate faults such as cable ruptures deteriorates
Solution Approach 1:
The system is divided into galvanically isolated domains (emulation device and control unit) with separate measurement lines. Fault simulation is implemented through switching elements that can selectively connect or disconnect specific measurement lines or signal paths, enabling fault scenarios while maintaining isolation integrity.
Solution Approach 2:
Switching elements (such as relays or solid-state switches) are introduced as intermediaries between the galvanically isolated domains. These intermediaries can be controlled to simulate faults by opening or closing circuits, allowing fault injection without compromising the galvanic isolation barrier itself.
2Reliability
If galvanic isolation is maintained in battery emulation device, then safety is improved, but fault simulation capability deteriorates
Solution Approach 1:
Physical mechanical fault simulation (direct cable cutting) is replaced with electronically controlled switching elements. These switches can be actuated via control signals to simulate open-circuit faults, short-circuit faults, or connection failures, providing the same testing capability without mechanical intervention and while preserving galvanic isolation.
3Measurement precision
If measurement lines are added for precise voltage control, then voltage control precision is improved, but system complexity increases
Solution Approach 1:
Buffer amplifiers or voltage followers are introduced as intermediary components between the measurement lines and the control unit. These intermediaries high-impedance buffer that preserves measurement precision while isolating the control unit from direct connection to the high-voltage battery terminals, thereby reducing system complexity and improving safety.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables the simulation of fault states in battery control units, enhancing the testing of battery control units by accurately replicating fault conditions without compromising safety or precision, thereby improving the reliability and safety of battery control systems.
Implementation Method 1
a voltage source; an amplifier unit
Implementation Method 2
an amplifier unit for controlling the output voltage
Implementation Method 3
provided by a control unit and at least one emulation channel for emulating a battery cell voltage at a terminal of the control unit in accordance with a setpoint value predefined by the control unit and provided via a galvanically isolated interface
Data Source
AI summary
A battery emulation device for simulating a battery cell voltage at a terminal of a battery control unit in accordance with a setpoint value includes a control unit configured to determine the setpoint value and provide the determined setpoint value via a galvanically isolated interface; and at least one emulation channel, each including: a voltage source; an amplifier unit; connection lines for connecting the emulation channel; measurement lines; and a fault simulation device configured to simulate fault states.