Energy budgeting with electric vehicles proves to be especially crucial. The efficiency, dependability, and safety of the lithium-ion batteries depend greatly upon their electronic control or Battery Management System (BMS). The task of such a system is monitoring and regulating the charge and discharge of a battery. From the higher-level communication with the driveline about diagnosis, safety monitoring, measurement and control of the charge state of the battery, to the balancing of the individual cells – the BMS performs tasks on various functional levels. This type of energy and battery management can be validated with tests, virtual as well as real, in the early development phases under laboratory conditions. Therefore, hardware and software components among other things will be replaced through simulation models that will enable cost and time saving in the manufacturing process.
Against this backdrop at BFFT, where the design and testing of energy storage systems is also an essential part of the service portfolio, they developed a battery cell simulator in-house. With this, all of the components of a BMS can be thoroughly tested. Using programmable test cases (including voltage, temperature, line manipulation), the entire battery environment up to the individual cells can be simulated and manipulated. The tests run either fully automatic or can be manually controlled. The special thing about the in-house developed battery cell simulator is the modular construction: BFFT can deliver the system at a time specified by the customer and in an especially short time compared to what competitors offer at a low cost. Some of the simulators are for that reason already in operation by some customers of VW (Volkswagen) group.