Products / Battery Cell Simulator
BMS Tester & Battery Cell Simulator
Test how your battery management system measures cell voltages and responds to faults. A Battery Cell Simulator supplies controlled cell voltages and sensor signals, so you can repeat normal conditions and defined faults and check the BMS response.
What do you need to reproduce at the BMS?
Basis and scope
Use the brochure and the agreed configuration to confirm the required operating points, interfaces and fault options.
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From model to electrical reality
Apply a repeatable condition. Measure the BMS response.
A test sequence or battery model sets the cell and sensor states. The BCS reproduces them at the real BMS connector, so you can measure the controller’s timing, diagnostics and protective response. Pack-level power is supplied separately.
- 1Define
Set SoC, SoH, temperature, load and fault state.
- 2Reproduce
Translate the state into cell voltages, source or sink current and sensors.
- 3Verify
Measure the BMS decision, timing, protection and recovery.
Core product capabilities
A BMS tester built around the cell.
Use the released product modules to reproduce the electrical conditions a BMS must measure, balance, diagnose and protect.
Cell voltage simulation
Set every virtual cell independently from 0.1 to 8 V. Create nominal packs, precise threshold ramps and controlled imbalance without waiting for real cells to charge or discharge.
Active and passive balancing
Use source and sink variants to reproduce current flow in both balancing directions. Select the current capability according to the BMS topology and cell-voltage range.
Review precision under loadIntegrated fault insertion
Create wire breaks or open circuits, shorts across simulated-cell channels and polarity reversal within the cell-simulation electronics. The applied fault remains tied to the controlled channel.
See the fault scopeNTC and PTC simulation
Replace real thermistors with galvanically isolated temperature-sensor emulation and add defined sensor short circuits or wire breaks.
Leakage and coulomb measurement
Measure quiescent, leakage and balancing currents at cell level. Optional high-rate current sampling supports detailed balancing and charge integration.
Battery models and HiL
Run static sequences, integrated models or dynamic MATLAB and Simulink models. Connect the BCS to a real-time PC and the wider test bench through documented interfaces.
Explore battery cell simulationMeaningful cell-level evidence
Precision must remain credible while the BMS is balancing.
A no-load voltage value is not enough. The simulated cell must remain stable while the BMS sources or sinks current. Otherwise threshold, balancing and state-estimation tests become ambiguous.
The BCS combines regulated cell voltage with cell-current measurement so the applied state and the BMS reaction remain attributable under realistic balancing conditions.
Exact values depend on the selected module, voltage range and system configuration. The released system specification and quotation remain authoritative.
Controlled fault insertion
Inject faults inside the simulated cell channel.
Fault generation within the BCS electronics keeps the applied condition controlled and repeatable. The BMS response can be assessed from detection through protective action and recovery.
Open circuit and wire break
Verify interrupted measurement lines, connector faults and diagnostic response.
Simulated-cell channel short
Apply a controlled short to the simulated-cell channel and assess the BMS diagnosis, protective action and recovery.
Polarity reversal
Validate handling of incorrect wiring, reversed connections and assembly errors.
Extended system faults
Extend testing with NTC/PTC faults, insulation-resistance simulation, current-sensor emulation and project-specific switching functions.
Physical product identification
Choose the enclosure for your test system.
The enclosure identifies the physical family. Cell count, cell electronics, sensor simulation, faults, isolation, automation and DUT interface remain configuration-specific.
BCS Flex 5 HE
The most compact BCS Flex enclosure for table-top and focused cell-level configurations.
BCS Flex 12 HE
A compact rack enclosure for modular development systems and expanded functional scope.
BCS Flex 24 HE
A mobile mid-size rack for greater channel count and integrated BMS test functions.
BCS Flex 38 HE
The full-size platform for high-voltage, high-channel-count and complete BMS HiL configurations.
Modular system design
Start with the cells you need. Scale to a complete BMS HiL.
System size is selected together with current capability, sensor simulation, faults, safety, automation and the physical DUT interface.
Compact bench system
For AFE (analogue measurement front end), CMC (cell management controller) and BMS development, algorithm work, start-ups and research laboratories.
- Portable format
- Cell and optional sensor simulation
- Expandable architecture
Modular development system
A common range for BMS hardware and software development with balancing and fault testing.
- Source and sink options
- Fault Simulation Unit
- Break-out and safety concepts
High-voltage and EOL system
Multi-rack systems up to 1,500 V for complete packs, continuous validation and production testing.
- Automation for long-duration operation
- Climate chamber and multiplexer options
- Customer-specific interfaces
Complete test-bench options
BMS HiL safety integration
The DUT fixture and the simulated cells share one enable chain.
Where access to the BMS or cell-monitoring units must be controlled, the BCS Flex can be engineered with an interlocked side enclosure or integrated DUT drawers. The DUT mounts to a threaded grid plate; opening an access door interrupts the BMS HiL interlock, shuts down the complete system and leaves the BCS outputs de-energised.
Controlled DUT area
BMS and CMUs are mounted on a threaded grid plate inside the side enclosure or an integrated drawer.
Coupled interlock
The access door is integrated into the enable chain of the complete BMS HiL—not treated as a stand-alone cabinet switch.
De-energized access
When the door opens, the system shuts down and the BCS outputs switch to a de-energised state.
Project-specific engineering
Safety functions, connectors, DUT fixture and the required risk assessment are defined for the delivered configuration.
Automation and model-based testing
Open interfaces for the test environment you already use.
Control cell values, fault states and measurements through documented interfaces. The Battery Cell Simulator can operate as a focused cell-level instrument or as one coordinated component in a complete hardware-in-the-loop test bench.
comemso comframe software
Connect configured cell signals with the recorded BMS response.
The comemso comframe UI brings the configured test channels, measured values and test sequence into a shared workspace. Use the selected software functions to prepare repeatable conditions and retain the corresponding measurements for review.
Keep the applied stimulus, BMS response and acceptance criteria together. The available channels, fault functions and automation interfaces depend on the system and software configuration.
A passing BMS test also depends on a healthy test setup.
A broken connection between the BCS and DUT, or a fault in a simulator channel, can undermine a test result. The BCS controller detects supported connection and channel faults and identifies the affected module through its red error indicator. Software can read fault information through the CAN, Ethernet or EtherCAT interfaces provided in the selected configuration.
Deliberately injected DUT fault
Select a fault supported by the configured simulator, such as an open circuit. Specify its channel and application conditions, then define the expected BMS response for the test.
Unintended test-system fault
A connection or channel problem in the test setup. Check diagnostic flags before accepting the run and define how automation handles an invalid result.
A clear diagnostic status is one prerequisite for credible evidence; it does not prove every aspect of a test valid. Automatic stop, quarantine and retest behaviour must be defined in the integration.
Specify accuracy at the DUT connection, cable compensation, operating conditions and long-term stability for the selected BCS setup. Keep the applied cell stimulus, DUT response and test-system status in the record so these conditions remain traceable during result review.
Long-term measurement confidence
Keep BCS accuracy under your control.
Measurement equipment changes over time. The BCS supports fine adjustment in the software workflow and professional recalibration to preserve reliable cell-level results throughout the system lifecycle.
-
1
Fine adjustment
Correct small cell-voltage deviations through the BCS software workflow.
-
2
Service calibration
Use the released service process at comemso or through qualified service personnel.
-
3
SmartCal
Automate calibration and adjustment with a guided process, suitable reference equipment and a generated report.
A compact BMS platform can grow with the business.
A BESS customer expanded from a 24-cell development platform to two BMS test systems, each with 132 cell channels, 40 NTC/PTC channels, shunt and RISO simulation.
Customer system: High-voltage BMS testing — System of the Month.
Test scenario: one cell voltage falls below its limit
Illustrative test: keep the other simulated cells at their normal values and lower one channel through the controller’s defined threshold. Compare the voltage reported by the BMS, its diagnostic message and protective response. A channel is one independently controlled cell or sensor signal, not an entire battery pack.
Technical resources
Review the method, configuration and supporting documents.
Battery cell simulation in detail
Cell monitoring, balancing, precision, fault insertion, automation and BMS HiL design.
BMS climate and temperature testing
Environmental conditions, cable effects, temperature cycling and laboratory design.
BrochureBattery Cell Simulator
Current product architecture, applications, modules and system configuration examples.
ConfigurationDefine the complete system
Convert the DUT interface and test scope into a project specification.
Customer experience
Customer voices on BMS testing
“At TI, we know having the right tools and support makes innovation possible. Our broad portfolio of devices for battery management systems coupled with comemso’s proven results and accuracy with their battery cell simulator helps accelerate design time. comemso offers the ability to test and measure your system on a cell level with high precision.”
“Outstanding technical knowledge of comemso and customer application. High product quality and suitable for research.”
“The flexible simulation of real-world battery conditions with the comemso BCS allows us to automatically test different real-life scenarios from our customers of grid, automotive, and transportation area and identify & eliminate safety-critical factors to improve performance at an early stage.”
Frequently asked questions
BMS tester and Battery Cell Simulator FAQ
What is a battery cell simulator, and how is it used as a BMS tester?
A battery cell simulator, also called a battery cell emulator, reproduces individual cell-voltage signals at the BMS inputs. A configured comemso BCS can combine source and sink behaviour, measurement read-back, temperature-sensor simulation and electrical fault insertion.
This lets engineers verify the BMS response to defined normal, boundary and fault conditions without waiting for real cells to charge or discharge. A cell simulator tests controller behaviour; it does not characterise battery chemistry.
Is a battery cell simulator the same as a battery pack simulator?
No. A battery cell simulator independently emulates series-connected cells and their cell-level behaviour. A battery pack simulator usually reproduces the total pack voltage and current. Both can be combined in a complete BMS HiL system.
How many battery cells can the comemso system simulate?
The modular product family can be configured from 12 to 300 simulated cells, with 0.1 to 8 V per cell and total series voltages up to 1,500 V. The final configuration depends on the DUT, current requirements and additional functions.
Can it test active and passive cell balancing?
For passive balancing, the simulated-cell channel sources current into the BMS bleed resistor. Active-balancing tests can require source and sink operation, depending on the energy-transfer path. Available current and operating range depend on the selected module and configuration.
Which electrical faults can be inserted?
Depending on configuration, the scope includes wire breaks or open circuits, a short across a simulated-cell channel and polarity reversal. Complete systems can add temperature-sensor faults, insulation-resistance simulation, current-sensor emulation and project-specific fault paths.
Can a BCS test bench grow into an existing BMS HiL or automation environment?
A configured BCS can integrate through documented CAN, Ethernet or EtherCAT interfaces. comframe supports setup and manual testing; the selected interface and software scope determine further automation.
The linked BESS project shows how a development setup grew into two BMS test systems. Its cell and sensor-channel configuration is documented in the customer example.
Read the BESS customer story · Review comframe integration interfaces
What makes a battery cell simulator reliable for automated BMS tests?
Compare specified accuracy at the DUT connection, suitable source and sink ranges, cabling and compensation, load conditions, calibration, long-term stability and measurement read-back.
Diagnostics are also essential: comemso BCS reports supported connection or channel faults at the affected module and through the configured software interface. The automation must check these flags and define when a run is invalid or requires a repeat. A clear diagnostic status is one prerequisite for credible results, not proof of every test condition.
Review test validity and BCS self-diagnostics
Check the evidence for your setup: specified precision and measurement conditions, calibration and SmartCal, and a published BESS BMS customer application. These provide distinct technical and practical evidence; they do not establish an independent ranking of suppliers.
BMS-controller test planning
Replace real cells with a safe, controllable test boundary.
Specify the BMS, emulated cell and sensor channels, controlled faults and required evidence.