Professional Documents
Culture Documents
net/publication/355897272
CITATIONS READS
9 208
10 authors, including:
All content following this page was uploaded by Tobias Högerl on 05 November 2021.
Abstract—This paper deals with the emulation of lithium-ion the partial load efficiency due to the usage of low-voltage
battery cells/modules for the development and testing of battery MOSFETs [17]–[19] and, moreover, these allow for a fault-
modular multilevel management converters and any kind of tolerant operation [20] and advanced battery diagnostics [21].
reconfigurable battery systems with series, parallel and bypass
function. The developed emulator is based on a buck converter To enable further extensive research in the field of MMIs,
type with an isolated input voltage supply. A circuit board battery emulators are necessary. By the usage of emulators
with the form factor of two cylindrical 18650 battery cells was instead of actual Li-Ion batteries, general safety can be in-
developed, which can function as a replacement of a real battery creased in experimental setups since emulators contain fea-
cell/module for a laboratory setup. In addition to the imple- tures like over-current, over-voltage and short-circuit protec-
mented safety mechanisms, such as over-current, over-voltage
and short-circuit protection, a simplified electrical equivalent tion mechanisms. Furthermore, the number of potential error
circuit model is implemented on the integrated micro controller. sources and the overall setup time required can be reduced
Thereby, the dynamic electrical behavior of any battery cell can by elimination of battery charging time and assurance of
be emulated with low deviations from its real battery behavior. correct battery voltages. Basic approaches of battery emulators
Index Terms—Battery electric vehicle, Battery emulation, were previously reviewed by [22], [23]. The published results
Battery management systems, Buck-Converter, Cell Emulation,
Hardware-in-the-Loop, Lithium-ion battery, Modular multilevel do not satisfy MMIs’ dynamic requirements since the BM3
converters, Modular multilevel inverters. modules should be reconfigured in a typical update frequency
of 20 kHz, whereas the emulation method reaches only a
I. I NTRODUCTION minimum latency of 100 ms or shows unstable behavior at
The increasing demand of automobile vehicles in combina- high update frequencies. Other approaches like the ones pub-
tion with local emission standards requires efficient ways of lished in [24], [24]–[28] focus on conventional permanently
transportation [1]. Therefore, battery electric vehicles (BEVs) connected battery packs’ behavior which cannot be compared
enjoy rising sales figures regardless of their drawbacks in to a BM3-based vehicle. The approaches need high amounts
range, cold climate performance and required charging time of computing power for the underlying simulations or do not
in comparison to internal combustion engine vehicles [2], accomplish the requirements in battery modeling accuracy.
[3]. In conventional BEVs, the traction battery can consist In contrast to [22]–[24], [24]–[28], the contribution of this
of up to several thousand individual lithium-ion (Li-ion) cells, paper is to suggest a battery emulator for the modules of a
which are connected into a fixed configuration [4], [5]. State- modular battery system with series, bypass and, especially,
of-the-art modular multilevel inverters (MMIs), which are parallel connectivity.
sometimes referred to as reconfigurable batteries, such as the II. S TATE - OF - THE - ART
ones reviewed in [4]–[13], can potentially reduce the before A. Battery Modular Multilevel Management (BM3) converter
mentioned drawbacks as well as increase vehicles’ safety. Fur- system
thermore, modular batteries based on MMIs potentially reduce
the amount of electromagnetic emissions [14]–[16], increase As described in [4], the BM3 converter system is a battery
cell or module-based modular multilevel converter topology.
Similar as other multilevel converters, the BM3 converter
This research is funded by MORE/ELAPSED as part of dtec.bw - Digitiza- system can create multiple discrete output voltage levels, but
tion and Technology Research Center of the Bundeswehr which we gratefully in addition, it can potentially replace the dedicated battery
acknowledge.
Furthermore, the financial support provided by the Swedish Energy Agency balancing circuit of a traction battery. Each of the BM3
(Energimyndigheten) is gratefully acknowledged as well. converter system’s modules mainly consist of a battery cell
Since the battery cells are switched into different states and,
therefore, experience different current loads, the battery pack
cannot be emulated as a single cell similar to a system with
permanently connected cells. Thus, for each battery cell, an
individual voltage source has to be provided. These voltage
sources (cells) must each dynamically represent the battery
Fig. 2. Valid switching states of two interconnected BM3 modules according
cell’s state model including state of charge (SoC), state of
to [4]: a) bypass connection; b) series connection; c) parallel connection. health (SoH) and impedance behavior in accordance to the
charge/discharge process during operation.
connected between point A and D of the first and last module,
respectively. In the schematics, the MOSFETs are replaced C. Battery modeling
by ideal switches for simplification reasons. Bypassing (see Since the Li-ion batteries’ voltage responses to an applied
Fig. 2a) all modules is achieved by activating the switches Si1 , load change have a high impact on the BM3 system’s func-
with i being the consecutive indicator for each module, and tionality, it is important to be able to reproduce a realistic cell
deactivating all other switches. This leads to an output voltage behavior. Therefore, an equivalent circuit model (ECM) is used
of 0 V, measured at the load resistance Rload . The second to describe the cells’ dynamic load response. As described
in [31] a typical cell model is based on a constant voltage source must also be switchable to an ’off’ state (0 V). Since the
source with an ohmic resistor (R0 ) and an inductor (LR ) in cells can be connected in parallel, series or be bypassed, the
series as well as several RC-pairs, as shown in Fig. 4. The cells themselves mainly experience pulsed currents (usually
20 kHz).
When connecting several cell emulators in parallel, the
R1 R2 R3
LR R0 maximum current should increase by the number of cells, so
that in total, a maximum current of
VOCV C1 C2 C3 Imax,tot = n · Imax,cell (4)
can be expected (3 cells in parallel means a current capa-
bility of at least 18 A as source or 9 A as sink). Self-excited
oscillations of the power supplies that exceeds the following
Fig. 4. Dynamic battery ECM with three RC-pairs [31].
time base limits, as well as voltage jumps above the tolerance
Li-Ion battery cell’s overall impedance for an ECM with three given below, shall not occur. The control speed for load steps
RC-pairs can be calculated by (0 A → 5 A → 0 A) must be correspondingly fast, so that the
deviation from the set output voltage, for both load steps is
3
X Rn tjp < 40 µs at V jp < 50 mV. The cell current limit must be
Z̄Cell,3RC = jωLR + R0 + (1) individually adjustable for each cell in ∆I = 10 mA steps.
n=1
1 + jωRn Cn
The cell voltage setting shall be individually adjustable per
As described in [31], the before shown three RC-model can cell in 10 mV increments.
be extended by an additional Warburg impedance. This model The cell impedance setting must be realized individually
is depicted in Fig. 5. The Warburg impedance element is used per cell by a hardware controlled impedance. It ranges from
to model the battery’s impedance behavior better at low load 1 mΩ to 200 mΩ, with a response time of less than 50 µs. Each
frequencies. The Warburg impedance can be calculated by voltage source represents a real battery cell’s characteristics,
i.e. SoC, SoH and impedance behavior according to a resistor,
LR R1 R2 ZW inductor and capacitor (RLC)-based ECM as described by (3).
R0 W The battery cell emulator must be able to measure the pulse
currents and calculate as well as adjust the current SoC in
RL C1 C2 the corresponding battery model via a Coulomb counter. For
VOCV
this purpose, the battery model must be calculated locally on
the device because of the fast response times. The integrated
Coulomb counter is a core component since it delivers an input
signal for the stored battery cell model. Therefore, its update
Fig. 5. Dynamic battery ECM with three RC-pairs and an additional Warburg
impedance element [31]. rate and accuracy influence the accuracy of the entire system.
The Coulomb counter’s update rate must be at least twice as
1 high as the measured signal’s frequency.
Z̄W = (1 − j)σω − 2 (2) An external query of the battery states must be possible with
Hence, the three RC-model’s total impedance including the at least 1 Hz via the network. An external trigger initiates a
Warburg impedance is given by time-synchronous (T < 5 µs) current and voltage measurement
on all cells. Within the emulated cell, current and voltage
RL + jωLR R1 must be measured simultaneously with at least 200 kHz for
Z̄Cell,Warburg = + R0 +
jωLR RL 1 + jωR1 C1 each cell. The triggered measurement duration must be at
1
R2 + (1 − j)σω − 2 least 100 ms, at maximum sample frequency. Because of the
+ − 1 measured data’s large amount generated in a short period
1 + jωC2 (R2 + (1 − j)σω 2 )
(3) of time, an integrated memory module must be installed on
the emulator. This serves as a temporary storage for the
III. BATTERY EMULATION REQUIREMENTS measurement data, which will be read out afterwards via the
The cell emulator can consist of any desired number of network.
cells depending on which output voltage is desired. Each cell The current measurement’s accuracy shall be better or equal
simulates the characteristics of a real battery cell in charge and to 1 mA in the measurement range below 1 A and 10 mA in
discharge operation. The battery model’s characteristics need the measurement range above 1 A. The voltage measurement’s
to be configurable through a user interface. The individual deviation shall be better or equal to ±5 mV. Ethernet or Ether-
emulated cells are connected via BM3 modules. Each cell CAT should provide the data transmission while control and
contains a voltage source, which provides a voltage of at least readout of the data shall be possible via MATLAB or Script.
2 V to 5 V with 6 A source current and −3 A sink current. A The isolation voltage to ground potential as well as between
cell’s continuous power should be at least 25 W. The voltage the cells must be at least 200 V. A short-circuit and overload
protection must be provided to protect the voltage sources IV. H ARDWARE AND SOFTWARE DESIGN
and the tested power electronics circuitry. A summary of the For the purpose of emulation, the behavior of a real cell
battery emulator’s main requirements is given in Table I. is divided into subsections, which have to be individually
realized in hardware. They are divided into long and short-
TABLE I
term, charging and discharging as well as impedance behavior.
BATTERY EMULATOR ’ S MAIN REQUIREMENTS The cell emulator’s key components are a laboratory power
supply with a buck converter connected to each output (see
Specification Fig. 6). Each combination acts as one emulated cell and
Requirement
Details Value can deliver a maximum output voltage of 5 V as well as a
Voltage range Possible single source voltages 0 V & 2-5 V maximum current of 10 A. This results in a maximum power
Cell maximum source current 6A output of 25 W per channel and thus fulfills the current,
Cell maximum sink current −3 A voltage and power capability requirements.
Current capability
System maximum source current n · 6A
System maximum sink current n · (−3 A)
Maximum power Single cell continuous power 25 W
Current limit Adjustable step size 10 mA
Voltage limit Adjustable step size 10 mV
Load jump Time based deviation at <50 mV <40 µs
Range per cell 1-200 mΩ
Impedance
Response time <50 µs
Coulomb counter Update frequency 100 kHz
Current accuracy (<1 A) 1 mA
Measurement Current accuracy (>1 A) 1 mA
Voltage accuracy ±5 mV
Isolation voltage Electrodes to ground potential 200 V Fig. 6. Schematic overview of n parallel cell emulators in a battery cell
holder.
Usual update frequency 1 Hz
Communication Delay after burst trigger <5 µs The long-term behavior includes SoC and SoH mapping.
Burst update frequency 100 kHz For this purpose, a bidirectional current sensor is placed at
Burst measurement duration 100 ms the emulator’s output to monitor the charge carrier flow Q
in both directions. The measurements are fed back to the
micro controller (µC) to set the reference output voltage Vref
Different discharge currents can lead to differences in the accordingly at the buck converter (see Fig. 7). The actual
SoC or the cell voltage. These lead to equalizing currents output voltage Vact is also measured and fed back to the µC to
[32] between the voltage sources when switching the cells correct the voltage set at the buck converter. The output voltage
in parallel. Although the resulting currents will be reduced by is set via a µC-driven, digital potentiometer, connected to the
dedicated algorithms such as reviewed in [33], the robustness feedback input and to the output voltage via a voltage divider
of the system must be such that any equalizing currents occur- (see Fig. 8).
ring between the cells in parallel operation do not cause any
damage in the emulator’s circuitry. In addition, an operating
strategy must be provided to control the equalizing currents.
Focus lies on the emulated cell’s voltage oscillation avoidance
when connected in parallel with other cells. The measurement
of the Coulomb counter must be fast and accurate enough to
cope with the small equalizing current flowing between two
cells with different voltage levels when switched into parallel
Fig. 7. Simplified control loop of the cell emulation.
connection. Due to the system’s losses, as reviewed in [18],
a temperature-controlled cooling or heat dissipation system The output voltage results to
must be provided to ensure operation for a time period of
at least 1800 s (length of the Worldwide-harmonized Light R1
Vout = Vref · (5)
vehicle Test Procedure). R2 + 1
The cells shall be set up in a maximum of three 19 inch For the purposes of energy efficiency and fast response times,
control cabinets in the form of card slots, whereby several the µC uses a lookup table for SoC and SoH which can be
cells may be combined in one slot. The peripheral devices for programmed to match with different cell properties like cell
implementing the functional scope are also to be included in aging effects, cathode chemistry and form factors as well as
this setup like the required protective circuits to ensure safe damage symptoms. The short-term behavior includes the map-
operation in the laboratory. ping of faster and transient events like the impedance behavior
A battery cell’s frequency response results from chemical
processes and material as well as structure-related properties.
These can be represented by an ECM. Achieving a frequency
response similar to a real battery cell is one of this paper’s ma-
jor goals. By driving flexible and configurable resistance and
capacitance networks with the µC and a corresponding lookup
table, a wide variety of cells, cell types and aging states can be
represented. The ECM used to accomplish a realistic battery
cell behavior was derived from [31]. A battery electrochemical
impedance spectroscopy (EIS) spectra is shown in Fig. 10.
For the time being, the inductive part is neglected, because
of the increased difficulties in switching the inductance with
transistors due to the current-driven behavior. An EIS of
Fig. 8. Implementation of the feedback voltage divider with a digital
potentiometer including the control via µC and I2C bus. the electronic circuit will also show whether the inductive
behavior can be influenced by the line inductance of the power
supply and discharge lines. An alternative approach includes
with load dips and peaks. The emulator’s short-term behavior pluggable RLC-modules to adjust the frequency spectrum.
is particularly important since pulses with a frequency up The modules, which are pre-assembled to match a certain
to 20 kHz through BM3 module reconfigurations are to be frequency behavior and different cell types, can be connected
expected. Because of the buck converter’s low bandwidth, a to the cell emulator via defined plug-in connections.
fast responding regulator is connected in series with the buck
converter to improve the cell emulator’s response time and
impedance behavior. The output regulator compensates the
highly dynamic voltage dips and peaks but otherwise follows
the specified output voltage.
The emulated cell’s impedance behavior can be controlled
by a binary graded resistor network as shown in Fig. 9, which
is substituted by a digital potetinometer with 127 resistor
values, in favour of a smaller PCB footprint. Both the buck
converter and the linear regulator have a digital potentiometer
in the voltage divider of the feedback branch. The regulation
of the resistor network, and thus of the emulated cell, is
realized via the µC which receives the output voltage Vact
as well as the charge flow Q as input. The buck converter’s
Fig. 10. Relationship between the EIS spectra and the equivalent circuit
model [4].
V. E XPERIMENTAL RESULTS
The following experiments were performed with the follow-
ing laboratory equipment:
• Power Supply: Rohde & Schwarz, Hameg, HMP4040 set
to 8 V and 10 A
• Measurement via an Analog Discovery I
• µC: STM32F411 ”BlackPill” Development Board
• Buck Converter: TPS54A24
As an initial test of the maximum control speed and the
follow-up behavior of the buck converter’s output, a µC was
Fig. 12. Dynamic behavior when a load step occurs from OL (open loop)
programmed to switch the binary cascaded resistors to GND to 0.5 Ω a) at Vcell = 3.94 V with additional 470 µF output capacitor b) at
according to a generated sine signal with an amplitude of Vcell = 3.94 V without additional output capacitance.
V̂sig = 1.5 V and a frequency of up to fsig = 1 kHz. This
results in a sine-shaped output voltage of Vout = [1.8; 6.1] V The ability of connecting two ore more modules in parallel
with an amplitude of V̂ = 3 V at the given frequency. to receive higher output currents is a major requirement. To
The maximum frequency achieved by the buck converter test this, a module was first loaded with a load of RL = 0.5 Ω
is fsw,max = 910 Hz. From this frequency upwards, signal load while the temperature winding was recorded with a
distortion starts. The blocking capacity on the input side thermal imaging camera and the drawn current was measured.
is increased to Cin = 1.8 mF after this test, which leads Subsequently, two modules were connected in parallel and
to a reduction of the ripple on the power supply side to exposed with a common load of RL = 0.5 Ω. Again, both
Vrip = 500 mV. the temperature development and the current drawn per board
To test the response time at different output voltages, the were measured comparatively. The results given in Tab. III
buck converter was set to its minimum and maximum output show that a parallel connection of two modules results in
voltage at a fixed switching frequency of fsw = 356 kHz (see the desired halving of the current through each cell. Heating
TABLE III
T EMPERATURE AND CURRENT MEASUREMENT OF PARALLEL CONNECTED
EMULATOR MODULES
Modules 1s 1s2p
V cell 4V 4V 4V
Icell 8.02 A 4.12 A 3.89 A
Itot 8.02 A 8.01 A
T 100°C 50 °C
VI. C ONCLUSION