Heinzinger Automotive simulator test

Heinzinger Automotive Test Systems
Battery Simulation

Battery Simulation

To test hybrid or all-electric drive systems, real batteries or a battery simulator can be used as the energy source. If reproducible results are needed, the battery simulator is the better choice since the properties of a battery can be determined by a range of parameters.
To be able to simulate a high-voltage battery with ideal properties or as closely to real conditions as possible, particular demands are made of the source / sink system used.

Conditions for the successful simulation of HV batteries

The fundamental requirement is a stable output voltage which can be controlled with high dynamism and precision even with rapid load changes. The ERS series meets this requirement by using complex and flexible digital control algorithms, implemented with DSP and FPGA structures, as well as fast-cycled power semiconductors.

The digital setup of the control circuit means that even the battery’s internal resistance can be mapped with a high degree of dynamism. Depending on a specified internal resistance and the momentary current value, a new voltage target value (battery terminal voltage) is calculated and controlled with each control cycle (48 µs).

As an option and in addition to the standard internal resistance control, further highly dynamic battery models (R-C links) can be made available inside the device via the control circuit. The output values are also recalculated with this option every 48 µs.

Safety for the test subject: current limiter, target value specifications, monitoring of data communication

Various safety monitoring systems are integrated to protect the connected test subjects.
If there is a malfunction or short-circuit, all of the devices have an adjustable current limiter as standard:

  • The OCP (Over Current Protection) function allows rapid disconnection if the threshold value is reached.
  • The same applies for voltage. This is monitored via an OVP (Over Voltage Protection) function. If the set value is exceeded, this also leads to a safe disconnection of the device.

To protect the test subject from incorrect operation of the device, additional parameters are applied that limit the target value specification in manual or remote mode to the permissible range and therefore protect the test subject against excess current, excess voltage and overload.
Where the ERS is controlled automatically via a process control system, data communication is continuously monitored. If the connection is interrupted or ceases to function, the system for equipment and test subject protection switches to a safe and secure state.

Integrating voltage profiles in real time

An extremely fast change rate in the target value specifications can be implemented via a digital CAN interface, which is already included as standard, at up to 1 kHz. This allows voltage profiles (e.g. from external customer-specific battery model calculations or previously demonstrated driving profiles) to also be integrated into the battery simulation in “virtually real time”.

Insulation monitoring function for earth fault monitoring

An insulation monitoring function is available for applications that require earth fault monitoring of the connected test subject. Earth fault monitoring is used as additional protection of the connected consumer and is frequently used in the battery simulation application.

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