CASE STUDY

180 kW Battery Tester/Emulator for Flanders Drive

Tags: PHIL, Rapid Control Prototyping, Automotive, Electric Vehicle, Battery Testing, Battery Emulation Contact us Print

About the project

Triphase delivered a 180 kW battery tester to Flanders Drive. It is part of a setup for battery characterization and lifetime testing. The battery tester features 2 output channels up to 1300V and 500 A. Moreover, it is fully programmable allowing for arbitrary test waveforms as well as power-hardware-in-the-loop setups. The setup can also be reconfigured to operate as a battery emulator. Finally, the system features both time-based and event-based data logging. It also supports test automation via its Python scripting interface.

Highlights

  • Battery testing and emulation up to 1300 V and 500 A
  • Reconfigurable modules that can be connected both in parallel and in series
  • Supports arbitrary waveform generation and power-hardware-in-the loop testing
  • Web-based graphical user interface
  • Time-based and event-based data logging
  • Test automation via the Python-scripting

The setup

The figure below outlines the battery pack test bed installed at the Flanders Drive laboratories in Lommel, Belgium. The setup supports arbitrary charging and discharging profiles being applied to a battery pack under test. At the heart of the system are two 90 kW Triphase PM90I30F03 converter modules. The modules can either be connected in parallel, for high current operation, or in series, for high voltage operation. The modules can also be configured to operate as voltage sources, thereby allowing for battery emulation as well as battery testing.

This setup enables researchers to both characterize battery packs, identifying battery model parameters. They can also study the effect of charging and discharging profiles on battery behavior and lifetime. This is important information in helping engineers to select the right battery for the right job.

Given battery models, researchers can also program the system to mimic a particular battery’s behavior. This allows them to study the impact of a battery’s behavior on connected devices such as motor drives or grid front-ends. Again, this is useful to compare batteries and to select the proper battery for a particular application.   

Through the interface, researchers can automate procedures for test and data analysis. This saves valuable time Python scripting in executing lengthy or repetitive tests.

The setup consists of:

  • Two PM90I30 90 kW isolated front-ends
  • Two PM90F03 90 kW DC/DC converters that can be connected in parallel or in series
  • A switching cabinet to automatically select the desired configuration

Scope of delivery and customer developments

Triphase Products

Triphase Services

  • Customized switching cabinet for automated system configuration
  • CAN interface for battery management system (BMS) integration
  • RS232 interface with supercaps
  • Automated start-up and shut-down procedures
  • Active grid interface and management of the power flow between grid and battery

Customer Implementations

  • Analysis of battery behavior and lifetime for different test cycles
  • Battery modeling and battery model identification
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