The battery emulator is emerging as a crucial resource in the electrification revolution, particularly in the development of electric vehicles (EVs).
Thanks to its ability to accurately replicate various battery characteristics such as voltage, capacity, charge and discharge levels, faults, or anomalies it enables advanced testing without the need to use (and thus deplete) physical batteries.
This approach ensures greater safety, operational flexibility, significant cost savings, and remarkable speed in development and validation processes essential elements to address the challenges of the modern industry.
Recently, CustoM 2.0 developed a test bench to perform charge and discharge cycles on batteries, interfacing with the vehicle’s Battery Management System (BMS) via CAN bus communication.
This system allows the evaluation of battery performance over time and under various environmental conditions.
The batteries are housed in a climate-controlled shelter equipped with all necessary safety measures to prevent direct contact and mitigate risks of ignition or explosion related to electrochemical reactions.
In addition to battery testing, this bench can also be used for debugging control units or powertrains, acting as a true battery simulator.
Technical Specifications of the Battery Emulator System Provided by CustoM 2.0:
- Bidirectional DC power supply of 144kW, 320A, 1500V, with battery simulator and charger functionality.
- Modular hardware, consisting of a parallel configuration of 2×4 modules (2 masters, each with 3 slaves), each with 18kW and 40A, interconnected by a fibre-optic loop for synchronization and parallel balancing.
- Electric power is managed through Staubli 1500V high-current connectors to ensure reliability and safety.
- Integrated safety systems, including a measurement basket with LED bar indication and a safety basket that cuts off the power supply and monitors conductor insulation.
- The system is completed by a PC with Eurins AdaMo© automation software, integrated with a plugin for controlling the battery simulator via the CANopen protocol.
CustoM 2.0’s Contribution to the Electric Transition
By providing this integrated battery emulator test bench, CustoM 2.0 makes a tangible contribution to the transition towards a more electrified world. This system ensures safety, flexibility, cost savings, and speed in development and testing processes essential values for the modern industry. The innovation promoted by solutions like this supports technological progress in strategic sectors such as electric mobility, renewable energy, and portable devices.
CustoM 2.0 Services and engineering solutions in the EV POWERTRAIN INTEGRATION SYSTEMS, ELECTRIFICATION, TESTING SOLUTIONS
