Developing Battery Management
System using Simulink
Chirag Patel
Application Engineer
MathWorks
© 2015 The MathWorks, Inc.
1
Agenda
▪ What is BMS and what engineers worry about?
▪ Start with single battery cell and build a pack
▪ Design BMS algorithms
▪ Generate code and deploy
▪ Model V&V
▪ Hardware-in-Loop testing
▪ Summary
2
What is BMS?
Software Electronics Battery Pack
Supervisory tasks
SOC estimation
Contactor management
Isolation monitoring
Fault detection and recovery
Thermal Management
Current & Power Limits Block Voltage,
Temperature Measurement
Cell Diagnostic
Cell Balancing 3
Motivation
Collaboration Gap Long Iteration Cycles Safety Critical System
Multi-Domain Modeling Simulations and Code Model V&V and Hardware-In-
Environment Generation Loop Testing
4
Where do we start?
Gain insight into cell behavior and model it
5
Equivalent Circuit Model
Transient
Dynamics
Cn Terminal
C1
Im R0 Resistance
I1 R1 In Rn
Open-Circuit
Voltage Ip
+
V
Em Zp
+ Parasitic
Ep Losses
[Ex Rx Cx] = f(SOC, Temperature…)
6
Battery Cell Blocks in Simscape
▪ Chose block for fidelity and simulation speed
▪ Parameterize as function of SOC &
Temperature
▪ Add thermal and fade effects
▪ Create custom battery blocks using
Simscape language or Simulink
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Parameter Estimation
R1 Goal:
Model should match real data as closely as possible
R0
Em C1
model (Em,R1,R0,C1) out
in =
experiment out ☺
8
Parameter Estimation
Before
After
9
Look-up Tables
Repeat parameter estimation for each
Temperature break-point in LUT
Em SOC SOC SOC SOC
…
(Volts) 1 0.9 0.8 0
5°C
20°C
40°C
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Start with Simulation
Battery Cell → Large Battery Pack
Pack System
Cell Dynamics
Thermal Model
Demo
12
Evaluate System Behavior
Demo
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Discharge + Charge
Cell Voltages Temperatures
Pack Current SOC
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Discharge Only
Cell Voltages Temperatures
Pack Current SOC
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Charge Only
Cell Voltages Temperatures
Pack Current SOC
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Evaluate SOC Estimation
Coulomb counting EKF
UKF
true
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Generate C/C++ Code From BMS Algorithm Models
Demo
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Did we generate code too early?
Is this ready to ship?
What if there are bugs?
Where are they? How do we find them?
Let’s
Find
Out
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Why Testing, Verification and Validation
Safety Critical System Functional Safety Certification
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Typical Development Workflow
Unit test finds some Errors found during
Most errors introduced
errors integration or in field
Requirements Specification
C/C++/HDL
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Challenge: Errors introduced early but found late
Unit test finds some Errors found during
Most errors introduced
errors integration or in field
Requirements Specification
C/C++/HDL
22
Validate Design via Desktop Simulation
Unit test finds some Errors found during
errors integration or in field
Design
Requirements C/C++/HDL
Model
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Model-Based Design Workflow
Simulink Models
Model used for
Design
Requirements production code C/C++/HDL
Model
generation
Generated code
Code
Generation
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Model-Based Design Verification Workflow
Model Verification Code Verification
Discover design errors at design time Gain confidence in the code
Review and
Component static analysis Equivalence
and system testing
testing
Equivalence
checking
Simulink Models
Model used for
Design
Requirements production code C/C++/HDL
Model
generation
Generated code
✓ Faster development ✓ Reduced cost
✓ Less hassle ✓ More Engineering Code
Generation
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How do we test?
Is it functioning
correctly?
Simulink Models
Model used for
Design
Requirements production code C/C++/HDL
Model
generation
Generated code
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Systematic Functional Testing with Simulink Test
Test Case Model Sim through SIL, PIL and HIL
Scale with PCT and CI
Inputs Assessments
MAT file (input) MAT file (baseline)
Signal Editor MATLAB Unit Test
Test Harness
Test Sequence Assessments
Excel file (input) Excel file (baseline)
and more! Main Model and more!
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Create Test Harnesses
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Systematic Functional Testing with Simulink Test
Use Test Manager to:
• Author, execute, manage test cases
• Review, export, report
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Manage and Organize TestCases
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How do we know we have enough test?
Does the Is it functioning Is it
design meet all correctly? completely
requirements? tested?
Simulink Models
Model used for
Design
Requirements production code C/C++/HDL
Model
generation
Generated code
31
How do we know we have enough test?
Does the Is it functioning Is it
design meet all correctly? completely
requirements? tested?
Simulink Models
Model used for
Design
Requirements production code C/C++/HDL
Model
generation
Generated code
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Integrate with requirements tools and author requirements
External
Requirements Simulink Requirements • Import from:
• Word / Excel
External Requirements • IBM® Rational® DOORS®
Import • ReqIF™ standard
• Update synchronizes
Update
changes from source
• Edit and add further details to
import
Authored Requirements
• Author requirements
Requirements • Export ReqIF
Managements • Enables roundtrip with
Export external tools
Tools
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Import External Requirements & Author New Requirements
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SW Requirements - Implementation Status
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Track Implementation and Verification
Implementation Status Verification Status
Implemented Passed
Failed
Justified
Unexecuted
Missing
Missing
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Requirements Verification with Simulink
Requirements Simulink / Stateflow
Implemented
By
Verified
By
Test Case
Inputs Assessments
Test Harness
Signal Editor
MAT / Excel Test
MAT / Excel File (baseline) Assessments
file (input)
Simulink Test
Test Sequence
MATLAB Unit Test
37
Link Tests to Requirements
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How do we know we have enough test?
Does the Is it functioning Is it
design meet all correctly? completely
requirements? tested?
Simulink Models
Model used for
Executable
Requirements production code C/C++/HDL
Specification
generation
Generated code
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Coverage Analysis to Measure Testing
Simulink
• Identify testing gaps
• Missing requirements
Stateflow
• Unintended Functionality
Generated Code
• Design Errors
Coverage Reports
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Measure Model Coverage
42
Addressing Missing Coverage
Partial Coverage
Test Cases from
Functional Requirements
Test
Generator
Simulink Design Verifier
43
Addressing Missing Coverage
Full Coverage
New Test Cases
Test Cases
44
Automatic Test Generation
45
Systematic Simulation Testing
Does the Is it functioning Is it
design meet all correctly? completely
requirements? tested?
Simulink Models
Model used for
Design
Requirements production code C/C++/HDL
Model
generation
Generated code
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Real-Time Testing of Battery Management System
Testing BMS with Battery Cells
– Longer test cycles
– Difficult to reproduce results
– Difficult to test fault conditions
– Limited test automation
Measurement &
Battery Pack Main Controller47
Diagnostics
Hardware-In-Loop Testing of Battery Management System
Testing BMS with Emulated Battery Cells
– Reduce testing time
– Test fault conditions safely
– Automate testing
Automatic
Code Generation
Wiring and Signal Conditioning
Measurement &
Battery Emulation Diagnostics Main Controller
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Challenges in setting up HIL testing for BMS
Execute Large Battery Models in Real-time
– Cell Voltages: ~100Hz
– Current: ~1kHz (Accurate Coulomb Counting & current derating
calculations)
– Cell / Pack Temperatures: ~1 to 10Hz (Large time constant for
thermal system)
Sensor and Fault Emulation
– Produce Isolated Voltages
– Sink and Source Current
– Support Series and Parallel Configuration
– Temperature simulation
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Execute Large Battery Models in Real-time
Prepare Model for Real-time Simulation (if using Webinar on “Real-Time Simulation of
Simscape) Physical Systems Using Simscape”
– Use Simscape Local Solver
– Configure fixed-cost simulations
– Try “Partitioning” option for non-linear systems*
Reducing model complexity
– Select right variant of battery block to match 2-3x
desired model fidelity
5x
5x
– Reduce order of charge dynamics by
selecting fewer number of time-constants
2-3x
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Sensor and Fault Emulation
Battery Emulation (IO991-06)
– 6 independent isolated channels
– Architecture allows series and parallel stack combinations
– Voltage range of 0-7 V with 14-bit resolution
– Source 300mA and sink 100 mA
Temperature Sensor Emulation
– RTD (PT100, PT1000) – low resolution 6 channel module
– Thermocouple – accurate 32 channels
– High precision resistor simulation modules
Fault Insertion
– 1A to 40A current handling; Up to 4 fault buses
– Electromechanical or MOSFET switches
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Conclusion
Leverage models to Test your design iterations Gain confidence in design
communicate technical every step of the way and work towards safety
specifications, design through simulations and certification
implementation, results Hardware-In-Loop testing
and maintain traceability
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Learn More about Battery Management System
Download Link to
File Exchange
For more info:
Chirag Patel
cpatel@mathworks.com
THANK YOU
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