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Battery Pack and BMS Test Systems

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Multiplexing: Reduce Cost and Complexity

Posted in Automated Test Stand Design, Automotive, Battery Pack and BMS Test Systems, Circuit Design, Custom Software and Hardware Development, Energy and Utilities, Green Technology, LabVIEW Programming, Telecommunications, Test and Measurement, Test and Measurement Automation

Multiplexing (Muxing) is an operation that selects one of many electrical signals and forwards the input into a single line. Demultiplexing (Demuxing) does the same operation, but in reverse, taking one electrical signal and outputting it onto one of many different wires depending on a selection. Muxing is an effective and relatively inexpensive wiring strategy that could reduce your circuit complexity and save you money. DMC has helped to implement muxing schemes on multiple projects and has witnessed...

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NASA Battery Simulation System

Posted in Aerospace, Automated Test Stand Design, Battery Pack and BMS Test Systems, Green Technology, LabVIEW Programming, Test and Measurement, Test and Measurement Automation

DMC leveraged our established Battery Management System (BMS) Testing Platform to deliver an automated Battery Simulator System to a NASA research group. NASA needed this system to facilitate development of highly specialized battery devices. These battery systems were designed to provide mobile power for advanced electromechanical systems such as Robonaut 2, a dexterous humanoid robot created to perform a wide range of tasks to assist astronauts on the International Space Station. The Battery Simulator...

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EV/HEV Battery Pack Environmental Exerciser/Monitor System

Posted in Automated Test Stand Design, Automotive, Battery Pack and BMS Test Systems, Green Technology, LabVIEW Programming, Test and Measurement, Test and Measurement Automation

DMC designed, built, and programmed a set of automated test stands for charging and discharging electric vehicle battery packs. The test stands also monitor the performance of these battery packs while exposed to harsh environmental conditions for extended timeframes. To provide the necessary testing bandwidth and flexibility required by the customer, DMC's solution included five test stands designed to test a single battery pack, and two test stands designed to test up to six battery packs at...

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Battery Control Unit Tester for Remanufacturing and Warranty Servicing Process

Posted in Automated Test Stand Design, Automotive, Battery Pack and BMS Test Systems, Energy and Utilities, Green Technology, LabVIEW Programming, Test and Measurement, Test and Measurement Automation

DMC utilized the DMC Battery Test Platform to develop a Test Control Panel software application to perform automated testing of the Battery Control Unit (BCU) for a Client's automotive lithium ion battery pack. This test system allowed the Client to instate an efficient process for evaluating the operating state of the Battery Control Units in battery packs returned under warranty claims, and thereby greatly reduced the cost of servicing these warranty claims.

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Battery Test System for Pack Remanufacturing and Warranty Servicing Process

Posted in Automated Test Stand Design, Automotive, Battery Pack and BMS Test Systems, Data Analysis, Data Mining, and Reporting, Energy and Utilities, Green Technology, LabVIEW Programming, Test and Measurement, Test and Measurement Automation

DMC utilized the DMC Battery Test Platform to develop a Test Control Panel software application to perform automated testing of a Client's automotive lithium ion battery packs. This test system allowed the Client to instate an efficient process for evaluating the operating state of battery packs returned under warranty claims, and thereby greatly reduced the cost of servicing these warranty claims.

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Relay Multiplexer Module with .NET Driver Library

Posted in Automated Test Stand Design, Automotive, Battery Pack and BMS Test Systems, Circuit Design, Custom Software and Hardware Development, Embedded Development and Embedded Programming, Energy and Utilities, Green Technology, LabVIEW Programming, Product Development, SDK, API, and Driver Development, Test and Measurement, Test and Measurement Automation

DMC delivered a low cost, high density Relay Multiplexer Module for a high channel count test application for a client in the performance racing automotive sector.  DMC provided the client with multiple methods for controlling and operating the device, including a soft front panel interface, a library of LabVIEW drivers, and a DLL package of .NET drivers.

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High Channel Count Thermistor Simulation

Posted in Aerospace, Automotive, Battery Pack and BMS Test Systems, Embedded Systems, Energy and Utilities, Green Technology, Test and Measurement, Test and Measurement Automation

As one component of a Client's complete test system solution, DMC was required to design and assemble a 50 channel temperature sensor simulator.  The resulting system is capable of simulating a collection of thermistor-based temperature sensors with 8-bit precision and 1% accuracy with 600V isolation between channels.

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SAE J1939 Controller Area Network (CAN) Drivers for LabVIEW Applications

Posted in Aerospace, Automotive, Battery Pack and BMS Test Systems, Embedded Systems, Energy and Utilities, Green Technology, LabVIEW Programming, Manufacturing Automation and Intelligence, Test and Measurement, Test and Measurement Automation

DMC developed a set of J1939 protocol drivers for LabVIEW which are based on the NI-CAN channel API provided by National Instruments (NI).  DMC needed to interface to a customer's automotive ECU over CAN using the SAE J1939 protocol as part of an automated test application.  Since the application was written in LabVIEW and the test station used NI-CAN hardware, the drivers were entirely written in NI LabVIEW.  The drivers provide functions at a layer above...

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Custom Relay Multiplexer System for High Channel Count Data Acquisition

Posted in Automated Test Stand Design, Automotive, Battery Pack and BMS Test Systems, Embedded Systems, Energy and Utilities, Green Technology, Product Development, Test and Measurement, Test and Measurement Automation

DMC designed and developed a relay-based multiplexing system for a Client's large-channel-count data acquisition system. For this project DMC was required to produce a reliable, yet low-cost, system to make current and voltage measurements using a high accuracy Digital Multi-Meter (DMM) on over 200 signal lines with 1kV isolation.

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Portable Battery Management System (BMS) Testing Demo

Posted in Automated Test Stand Design, Automotive, Battery Pack and BMS Test Systems, Green Technology, LabVIEW Programming, Test and Measurement, Test and Measurement Automation

An international partner requested a small scale Battery Management System (BMS) Test Station for demonstrating the basic battery simulation functions of a much larger test system. DMC responded by building a Demo Test Station that is easily transportable while still fully capable of simulating all the input signals (voltage, current, temperature) to a 6-cell battery pack BMS.

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Battery Stack Simulator for Hardware in the Loop (HiL) Testing of Electric Vehicles

Posted in Automated Test Stand Design, Automotive, Battery Pack and BMS Test Systems, Energy and Utilities, Green Technology, LabVIEW Programming, LabVIEW Programming for Real-Time and FPGA, Product Development, Test and Measurement, Test and Measurement Automation

 A battery stack simulator for hardware-in-the-loop (HiL) test systems is being produced by DMC to augment the capabilites of battery management systems (BMS) HiL test systems.  This system leverages DMC's vast hardware and software experience in Electric Vehicle (EV, HEV, PHEV) Battery Pack and BMS Testing.

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Battery Management System (BMS) Test Stand (2nd Generation)

Posted in Automated Test Stand Design, Automotive, Battery Pack and BMS Test Systems, Energy and Utilities, Green Technology, LabVIEW Programming, Test and Measurement, Test and Measurement Automation

DMC built upon its previous Battery Test Platform design experience to produce a completely automated test system specifically designed for Battery Management System (BMS) validation, verification, environmental, and Hardware in the loop (HWIL/HIL) testing. Numerous new features and functionalities were implemented in this second generation version of DMC's BMS Test Stand to meet the customer's latest testing requirements. To fully evaluate a BMS, the first challenge is to simulate all...

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CAN - Controller Area Network - Streaming Data Recorder

Posted in Automotive, Battery Pack and BMS Test Systems, Green Technology, LabVIEW Programming, Test and Measurement, Test and Measurement Automation

A Tier One automotive component manufacturer asked DMC to develop a low-cost, quick-turn, high channel count, CAN (controller area network) data recorder.  Using National Instruments (NI) CAN hardware, LabVIEW software and a low cost industrial PC, DMC specified, designed, programmed and delivered a complete system to the customer in less than two weeks.

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Batteries and Fuel Cells: Large-Scale Distributed Testing

Posted in Automotive, Battery Pack and BMS Test Systems, Embedded Systems, Energy and Utilities, Internet of Things (IoT), LabVIEW Programming for Real-Time and FPGA, Product Development, Test and Measurement, Test and Measurement Automation

A client in the research field came to us with a challenging large-scale project: building a large-scale automated system for testing energy storage devices, including batteries and fuel cells. The system had to be scalable to enable hundreds of parallel asynchronous tests on various devices, including smart HEV/PHEV/EV battery packs, single Lithium-ion and lead acid battery cells, multi-cell lithium-ion battery packs, “smart” CAN-enabled fuel cells, and bare fuel cell stacks. The...

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Smart Battery Pack Manufacturing Test

Posted in Battery Pack and BMS Test Systems, Consumer Goods, Green Technology, LabVIEW Programming, Manufacturing Automation and Intelligence, Test and Measurement, Test and Measurement Automation

DMC worked with a manufacturer of smart battery packs, which supplies batteries to several major portable instrument and medical device producers, to develop a custom software and hardware system that both programs and functionally tests the entire line of smart battery pack products.

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