Battery Simulator Central Bus Testing Apparatus
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Solution Overview
Problem
Existing test apparatus for battery control devices and batteries are complex, heavy, and not mobile enough for effective field testing, particularly in the motor vehicle industry where electric drives require efficient battery-electronics testing.
Innovation Solution
A simple and mobile test apparatus using a battery simulator connected via a central bus to an evaluation module, allowing for the simulation and processing of battery cell voltages, temperatures, and other quantities, with a control module coordinating the testing process and enabling selective cell balancing and temperature management.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If HIL standard test systems are used for battery testing, then testing reliability is improved, but device complexity and weight increase
Solution Approach 1:
The test apparatus is divided into modular components: a battery simulator with multiple cell channels, an evaluation module with isolating stages, and a central bus system. Each cell can be independently simulated and tested through separate isolating stages that can be selectively connected to the evaluation module, reducing overall system complexity while maintaining comprehensive testing capability
Solution Approach 2:
The evaluation module serves multiple functions: it evaluates battery control devices, simulates battery cells, measures voltages and temperatures, and provides isolating stages for selective cell testing. The battery simulator can function both as a test subject and as a test tool, enabling the same hardware to perform multiple roles and reduce device complexity
2Measurement precision
If HIL standard test systems are used for battery testing, then testing accuracy is improved, but mobility is reduced
Solution Approach 1:
The invention extracts only the essential testing functions from complex HIL systems: voltage simulation, temperature measurement, and cell isolation capabilities. By removing unnecessary components and focusing on core measurement functions, the system achieves adequate measurement precision with significantly reduced weight and improved mobility for field testing
Solution Approach 2:
The battery simulator creates simplified electrical copies of battery cells using voltage sources and measurement circuits that replicate cell behavior without requiring actual battery cells for every test scenario. This allows accurate measurement of voltage and temperature parameters while maintaining a lightweight, portable design
3Productivity
If all battery cells are tested simultaneously, then testing completeness is improved, but device complexity increases
Solution Approach 1:
The isolating stages provide dynamic reconfigurability, allowing the evaluation module to selectively connect to different cell channels based on testing needs. The system can dynamically switch between testing individual cells, groups of cells, or all cells simultaneously, enabling flexible testing strategies that adapt to specific test requirements without requiring fixed complex wiring for all possible test configurations
Data Source
AI summary
The invention relates to a test apparatus for checking a battery control device or for checking a battery having at least one cell, comprising a battery simulator (18) for simulating a voltage of at least one cell of a simulated battery for specification on the battery control device, wherein the battery control device or the battery is connected to an evaluation module (14) via a rail designed as a central bus in order to process and check the voltage of a selected cell, wherein the selected cell of the battery simulator for the battery control device or the selected cell of the battery can be selected via a separation module (24). In this way, a test apparatus for checking a battery control device or for checking a battery can be provided, which has a simple construction and can check all of the cells of a simulated or actual battery in a simple manner.