Battery Module PACK BMS Testing System

1. Equipment Overview

The Battery Module PACK BMS Testing System is a precision testing platform designed to validate the functionality and performance of Battery Management Systems (BMS) integrated into battery modules and PACKs. The system provides comprehensive testing, including communication protocols, balancing functionality, protection mechanisms, and performance under simulated conditions. It is essential for EV battery production, energy storage systems (ESS), and R&D applications.

2. Key Features

Comprehensive BMS Validation: Tests communication, protection, balancing, and thermal management.

Protocol Support: Compatible with common communication protocols (CAN, RS485, LIN, etc.).

Simulated Environments: Emulates cell voltages, currents, and temperatures for realistic testing.

High Precision: Accurate measurement and control of electrical parameters.

Customizable Profiles: User-defined test scenarios for diverse application needs.

3. Technical Specifications

3.1 Electrical Testing

Voltage Simulation Range: 0–5 V per cell (configurable for up to 32 cells in series).

Voltage Accuracy: ±0.02%.

Current Simulation Range: -200 A to +200 A (bidirectional).

Current Accuracy: ±0.1%.

Capacity Range: 10 Ah–500 Ah.

Balancing Current Simulation: 0–5 A per cell.

3.2 Communication Protocols

Supported Protocols: CAN, RS485, LIN, Ethernet.

Baud Rate: Up to 1 Mbps (CAN).

Error Detection: Monitoring of communication stability and integrity.

Protocol Customization: Configurable for proprietary or custom protocols.

3.3 Protection Function Testing

Overvoltage/Undervoltage Protection: Simulates threshold violations to validate BMS responses.

Overcurrent/Short-Circuit Protection: Verifies BMS safety shutdown mechanisms.

Thermal Protection: Tests BMS reactions to simulated temperature deviations.

3.4 Thermal Simulation

Temperature Range: -40°C to 100°C (simulated via thermocouples or RTD interfaces).

Temperature Accuracy: ±1°C.

Thermal Coupling: Supports testing for thermal management system integration.

3.5 Dynamic Testing

Load Simulation: Variable load profiles to mimic real-world conditions.

Cycle Testing: Programmable charge-discharge cycles with real-time BMS monitoring.

Fault Injection: Simulates failures (e.g., sensor disconnection, communication errors) to test BMS resilience.

3.6 Software and Control

User Interface:

15-inch touchscreen HMI.

Multi-language support (English, Chinese, etc.).

Data Management:

Real-time monitoring and graphical data visualization.

Export formats: CSV, Excel, PDF.

Test Programming: Flexible configuration for custom test cases.

Remote Access: Ethernet and Wi-Fi for remote monitoring and control.

3.7 Mechanical Design

System Configuration:

Modular design for easy expansion.

Fixtures adaptable to various module and PACK sizes.

Dimensions:

Length: 1,500–2,000 mm.

Width: 800–1,200 mm.

Height: 1,800–2,000 mm.

Weight: 800–1,500 kg.

3.8 Safety Features

Overvoltage/Overcurrent Protection: Ensures safety during operation.

Short-Circuit Detection: Immediate shutdown in fault scenarios.

Emergency Stop: Operator-accessible emergency shutoff.

Environmental Monitoring: Smoke and temperature sensors for additional safety.

Certifications: CE, UL, ISO 9001 compliant

3.9 Environmental Requirements

Operating Temperature: 10–35°C.

Humidity: ≤60% RH (non-condensing).

Power Supply: AC 380V ±10%, 50/60 Hz, 3-phase.

Power Consumption: ≤10 kW.

4. Applications

EV Battery Production: Ensures BMS functionality in modules and PACKs for electric vehicles.

Energy Storage Systems (ESS): Validates BMS used in grid-scale and residential storage systems.

Consumer Electronics: BMS testing for small devices and power tools.

R&D and Quality Assurance: Supports development and validation of BMS designs.

5. Maintenance and Warranty

Maintenance Schedule:

Weekly: Inspect communication interfaces and connectors.

Monthly: Verify voltage, current, and thermal simulation calibrations.

Annually: Comprehensive diagnostics and software updates.

Warranty Period:

Standard: 12 months.

Extended: Available upon request.