Our Centre of Excellence team pioneered breakthrough battery management system validation by creating an intelligent emulator platform that transcends traditional testing boundaries. Recognizing the automotive industry’s need for sophisticated, scalable BMS validation, we delivered revolutionary emulation technology that eliminates real battery pack requirements and live battery testing risks while opening new possibilities and establishing unprecedented safety, efficiency, and cost-effectiveness standards.
Business Goals
Traditional BMS development faced significant operational challenges demanding innovative solutions, as conventional approaches required expensive Hardware-in-the-Loop systems and multiple physical battery packs, creating substantial cost burdens and safety concerns Also, testing with real batteries introduced serious hazards, particularly during fault injection scenarios involving thermal runaway, short circuits, and overvoltage conditions.
And these edge cases were extremely difficult to test safely and repeatedly. Manual voltage control led to inconsistent, time-consuming validation cycles. Additionally, testing setups were inflexible, making it challenging to adapt to different battery configurations such as 6, 12, or 16-cell arrangements without significant hardware modifications. So, many organizations minimized end-of-line testing due to complexity and costs.
Solution
Our engineering team developed this as a innovation opportunity that redefines industry capabilities, creating an intelligent virtual battery ecosystem operating beyond physical hardware constraints, enabling unlimited testing possibilities. We built a solution leverages sophisticated emulation algorithms that recreate real battery behaviors with remarkable precision, dynamically modeling cell voltage, temperature responses, balancing actions, and protection events that mirror actual lithium-ion battery pack performance.
This reusable hardware platform eliminates expensive physical battery inventories while enabling thorough validation of voltage sensing, balancing, temperature monitoring, current protection, and communication protocols. The modular design provides instant scalability, supporting 1 to 28 series-connected cells for medium-power applications across diverse automotive configurations. With digital software control and easy integrations with automated test environments via USB or CAN interfaces, the emulator makes testing consistent, repeatable, and scalable.
Through this approach, developers can test BMS firmware or hardware changes immediately without waiting for physical battery packs, transforming both development validation and end-of-line production testing workflows while reducing development and production costs, increasing safety, and speeding up the testing phase.
Key Highlights
Next-Generation Virtual Battery Technology:
Engineered a complete digital battery environment replicating traditional lithium-ion behaviors, including dynamic voltage profiles, thermal characteristics, and performance variations with laboratory-grade precision.
Enhanced Fault Simulation Excellence:
Developed sophisticated simulation enabling controlled testing of overvoltage, undervoltage, short-circuits, overcurrent scenarios, and thermal runaway conditions with complete safety, unlocking validation scenarios previously impossible with physical batteries.
Universal Configuration Adaptability:
Built an intelligent modular architecture supporting 1 to 28 series-connected cells, enabling uniform voltage and temperature emulation with cellwise calibration capabilities for diverse medium-power automotive applications.
Production Automation Integration:
Created a smart software orchestration platform with proprietary automated testing routines, enabling smooth integration with development workflows, end-of-line production testing, and quality assurance protocols while eliminating manual setup requirements.
Outcomes
- 70% Acceleration in Development Timelines
- 90% Enhancement in Testing Safety Standards
- 60%+ Reduction in Conventional HiL Testing Infrastructure Costs
- Complete Validation Coverage Achievement for All BMS Functions
