Battery Pack and BMS Test Systems

DMC's Battery Test Stand for Harsh and Extreme Environmental ConditionsAdvanced battery systems are used to power a growing range of products, from cell phones, laptops and power tools to electric bicycles and full scale hybrid electric and plug-in electric vehicles. Emerging cell chemistries provide increasing energy density and expand viable battery applications while at the same time increasing the demand for effective electrical and thermal management of battery pack components. Modern smart batteries include embedded electronics called a Battery Management System (BMS) that serves as the “brain” of the battery pack, optimizing battery performance and ensuring that it operates safely.

DMC designs, builds, and programs automated systems for testing and validation of a broad range of battery pack and battery management system (BMS) designs. DMC’s modular Battery Test Platform incorporates open software and hardware technologies, along with flexible and reliable subsystem components and instruments, in order to create systems that are completely customizable to the end user’s specifications.

Battery Pack Test Systems

Click here to see DMC's latest Battery Production and Remanufacturing Test System

Vehicle Battery PackDMC's Battery Pack Test Systems facilitate battery design as well as research and development for national laboratories and research institutions. They are deployed in end of line / production test stations for battery packs developed by major automotive manufacturers and their suppliers. DMC’s battery pack test systems are designed to evaluate the battery as a complete system and validate a comprehensive range of battery pack functionalities, including:

  • Power performance, capacity, DCR / internal resistance
  • Contactor and safety interlock functions
  • Isolation / insulation resistances
  • Reporting of operating data through external communication interfaces (usually CAN)
    • Cell voltages
    • Pack / cell temperatures
    • State of charge (SOC)
    • Faults / Diagnostic Trouble Codes (DTCs)
    • Etc.
  • Electrical characteristics / continuity of internal pack wiring / signals
  • Cooling system operation

DMC test stands are designed to accommodate multiple battery pack testing regiments including:

  • Functional testing: to verify all battery pack communication and data reporting, safety features, wiring and component functions
  • High power battery cycling: to evaluate the power characteristics of a battery pack
  • Environmental/endurance testing: to test battery pack functions while exposed to harsh/strenuous conditions for extended periods of time

High Power Battery Cycling

DMC's Battery Pack Test Systems can be designed to include battery pack cycling. Our systems can execute standard and customized charge and discharge profiles. Our Battery Pack Test Stands can be integrated into battery cyclers and power supply/DC load platforms from any manufacturer including:

  • Aerovironment Cyclers (AV900, ABC150, ABC170, etc.)
  • TDK-Lambda
  • NH Research
  • Sorensen/Ametek
  • Amrel
  • TDI
  • Dynapower

BMS Test Systems

DMC’s BMS Test Systems support the development of laptop / consumer electronic batteries, high power lithium ion batteries for electric vehicles, and power modules for a humanoid robotic astronaut on board the International Space Station.

BMS Test System State DiagramFor BMS testing regiments, the Battery Management System is tested using a hardware-in-the-loop approach. The test stand itself simulates and controls all inputs to the BMS (cell voltages, temperature sensors, current sensors, CAN data, etc.), providing the ability to subject the BMS to a complete range of possible battery pack states and verify proper BMS responses across operating conditions. DMC’s BMS test systems are designed to evaluate a comprehensive range of BMS functionalities, including:

  • Measurement accuracy (cell voltages, temperatures, pack currents, etc.)
  • BMS power consumption
  • Cell balancing functions
  • Reporting of operating data on internal and external communication buses (usually CAN)
  • Pack management functions (state of charge calculation, thermal management, etc.)
  • Safety functions, contactor control, fault detection, DTC reporting

DMC test stands are designed to accommodate multiple BMS testing regiments including:

  • Functional testing: to verify all BMS communication and data reporting, safety features, wiring and component functions
  • Environmental/endurance testing: to test BMS function while exposed to harsh/strenuous conditions for extended periods of time

A more complete introduction to EV Battery and BMS testing is given in this article: EV Battery and BMS Testing in Validation and Production Scenarios. You can also view and download this document as a PDF here.

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