Electromagnetic compatibility testing in the comemso emv chamber
Battery Cell Simulation BCS test system
comemso Battery Cell Simulation

TESTING BATTERY MANAGEMENT SYSTEMS (BMS) WITH THE BATTERY CELL SIMULATOR (BCS)

Accelerate your BMS development and tests with the comemso BCS system as BMS HiL.
Always best-in-class since more than a decade.

We ensure that you get your BMS optimized, safe and robust.

Test and optimize your algorithms for active or passive balancing with the comemso BCS to enlarge the EV range and optimize health and aging of the battery cells.

Get here more information about the state-of-the-art Battery Cell Simulator, for testing Battery Management Systems as Hardware-in-the-Loop system (BMS HiL).

We offer a large mix of modules for BMS testing with scalable variants and different functions: with their modular design, comemso’s battery cell simulators offer a wide range of tailored solutions in combination with standard components. Thanks to this flexibility, we can implement systems in different sizes to best meet the needs of our customers.

We offer portable tabletop systems with 12 to 36 cells. These systems are ideal for chip manufacturers, start-ups or entry-level research. We also supply mid-sized systems with 24 to 60 cells that are of interest to developers of battery management systems or active and passive balancing systems. And we can also provide big racks with more than 204 cells in accordance with customer requirements.

With all comemso systems, battery management systems can also be tested from cell level to pack level. By using them you ensure that you develop a safe, energy-efficient and long-lasting product with long-range and reliable range indication. Regardless of their size, all of our systems can be configured as end-of-line variants for continuous operation and highes precision (less dynamic).

If you need help to specify your test bench depending on your BMS, our sales engineers are happy to support you. You can get a free LIVE product demo, feel free to contact us.

BASE

BATTERY CELL SIMULATOR (BCS)

The BATTERY CELL SIMULATOR is the core element of every BMS test system. Each module contains 12 virtual battery cells that electrically simulate real cells in electric vehicles. All of their properties can be parameterized and can therefore provide the battery management system with all the necessary states at cell level in a highly precise and dynamic manner. Static tests can be performed for extensive validation of balancing algorithms and security mechanisms, including combinatorics of multiple errors. In addition, dynamic tests are possible using integrated, differently parameterized comemso battery models on each cell or already connected Matlab models. With the dynamic tests, the state of charge (SOC), state of health (SOH) and history (log book) functions of the BMS can be checked. The electrical emulation of virtual battery cells not only enables the user to carry out extensive, but also safe, reproducible and fully automatic tests of the BMS. With the open interface for various software tool chains, comemso offers flexible options for different customer needs and powerful, ready-to-use test systems with very short training times.

An animated video of the possible functionalities can be found at the bottom of this page.

Latest Software / Firmware:
Gen7: Rel_01.21.00 / Gen8: Rel_08.01.00

BASE

POWER SUPPLY

A power supply unit (PSU) is the unit in the system that supplies the battery cell modules with the appropriate isolated module voltages. By regulating and stabilizing the voltage, it ensures the required currents for any load condition. There are two power supply size variants depending on the test bench size. In addition to the modules, other components from comemso can also be supplied.

comemso power supply

RECOMMENDED

SWITCHBOX

The SwitchBox has a number of tasks. On the one hand, it is a safe power distribution box for the various components of the test system and is suitable for 1 or 3 phases, 110/230V – 220/400V. With a main switch, emergency stop switch and various safety mechanisms, it corresponds to the safety guidelines and is therefore an important part of the safety of the overall test bench. There are different versions with different safety features such as isolation monitoring, emergency stop chain across multiple systems or remote control to meet each customer’s needs.

EXTENSION

FAILURE SIMULATION UNIT

The Failure Simulation Unit (FSU) emulates electrical line breaks in the cable connection between the battery management system (BMS) and the emulated battery cells. This error case can be set and simulated per each FSU module individually between 1 or up to 120 cells at the same time. This makes it possible to check how the BMS reacts to line breaks in the measuring and balancing lines to the cells, but also to simulate the “marriage” between BMS and cells – with different sequences and permutations.

comemso failure simulation unit

EXTENSION

NTC/PTC TEMPERATURE SENSOR SIMULATION

The NTC/PTC is used to simulate a temperature-dependent resistance in the value range from 0 Ω up to 8.1 MΩ, with a high resolution. It allows to simulate the thermal behavior by changing the resistance. In addition, it is optionally possible to simulate the fault case of a short circuit and a cable break. Thus, the behavior of the battery management system at different simulated temperatures and electrical faults can be represented.

comemso NTC / PTC

EXTENSION

R-ISO CHECK

The 2-channel R-ISO-Check card emulates the insulation resistance in the high voltage range between DC+ to PE and DC- to PE. The resistance value can be set in the range of 20 kOhm to 65 MOhm. This function is important because the BMS has to detect a possible dangerous isolation fault/connection of the battery with the chassis or other components outside the battery in order to pretect life and limb.

comemso Resistor-ISOlation card or device

BCS GENERATION 8

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