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The Modular Automotive High Power Lithium Ion Battery from PMS

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The modular PMS automotive high power battery

  

The PMS battery, technical data

 

This high power battery system consists of battery modules with 18 x 40 Ah cells, all connected in serial. Up to 5 of these modules can be connected in serial to form a tray of 5 x 18 = 90 cells.

 

Module data:

Module voltage max: 72 V

Module voltage nom: 63 V

Module voltage min: 55 V

Module power max: 11,5 kW

Size: 30 X 20 X 25 cm (width x heigth x depth )

Weight: 20 kg

 

System data:

System voltage max: 360 V

System voltage nom: 315 V

System voltage min: 280 V

System power max: 57,6 kW

DC current for 10 sec: 160 A

Size: 30 X 20 X 172 cm (width x heigth x depth)

Weight: 120 kg

 

The features of this battery in short

 

The battery system is modular, so that each battery module can be replaced individually by a simple plug technology. Each battery module has its own BMS with its own self diagnosis and error memory.The PMS high power battery has the following highlights:

1. Supervision of all cells voltages and all cell temperatures.

2. Supervision of the cell current and calculation of SOC, SOH and power prediction.

3. The ECUs of the charger and the electrical load informs the embedded battery controller which currents can be charged or discharged. The battery controller then controls the current via the converter.

4. The powerful self diagnosis detects all potential errors and enters them into the local error memory. The battery controller is the DTC master.

5. The battery controller can be polled for all diagnostic data via CAN. An UDS interface to the diagnostic tester is available.

 

The Battery Configuration and Monitoring Tool PMS Battery Control

For the development and process monitoring of your lithium ion battery you can successfully apply this Battery Control tool from PMS. PMS Battery Control supports you with all aspects of the development, the configuration, the system test and the process monitoring of the daily operation of your battery system. With PMS Battery Control you can exactly configure your battery with the specific data of your cell supplier. Each cell has for example different maximum and minimum voltage levels for charging and discharging and also the maximum charging and discharging currents are specific for each cell type. These data are entered into header files, which are integrated to the battery application software at each build. When you apply the operating system PMS StandOS you can even download these setting for testing purposes.

The CAN messages running in your battery system you can establish with the PMS UDS Diagnoser. For the creation of the embedded DTC error memory data bank, you can use the configuration features of the Config DTC window. How to react on critical errors, you can configure in the Action Matrix window. PMS supports active balancing, so for this task the Balancing windows helps you with these specific configurations. The EEPROM window supports you with the configuration of the data, which must by written and read before and after the sleep mode. The functions, which must be called in the states “GotoSleep” and “WakeUp” you can easily configure in the PMS StandOS Configurator.

When everything is programmed und configured the right way, you can run the Online Process Monitoring and Control by clicking on the hand icon, which then becomes a “Running Man” icon and the new state is displayed to the right of the icon. The Cell Data and the Block Data windows then will show all battery data of interest. The Query DTC and Diagnosis windows offers you the real time monitoring and recording of the all DTCs and all battery data. 

Functional Safety

 

The PMS Lithium-Ion automotive battery is a modular and safe high power battery to be applied in all automotive environments. The safety standards of automotive high security systems as for example ISO26262 are implemented in all systems from PMS. The PMS Automotive Battery is AutoSAR and ISO26262 compliant. The safety is implemented by dedicated hard- and software, by self diagnosis in the embedded system and by thoroughly testing on the basis of test scripts, striving for a 100% test coverage.

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 Hardware test configuration with the PMS Diagnostic Tester

 

Although the PMS automotive battery is trimmed for low cost, some expenses are invested in security hard- and software:

The cell sensors can send alarms via an alarm line and thereby directly put the system in a safe state, also without the interaction of the microcontrollers.
All important sensors and actors are redundant or can be sensed for functionality and plausibility.
All cell voltages and all cell temperatures are measured and monitored.
All ECUs are dual core systems, where each core monitors the other.
All CAN networks are constantly checked by lifebeat monitoring.
Ambient air temperature and humidity measurement and monitoring.
Control of the battery module cooling vent with current feedback.
The aging of the relays is monitored.
The isolation and the fuses are constantly monitored.

 

Dramatical cost reduction

The prices of Lithium Ion batteries is dropping constantly in a dramatic way. In a few years it is expected, that the prices fall far below 100€/kWh while the energy density rises above 300 Wh/kg. This is considered as the break through for Ecars.

 

Diagnosis and Testing

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The PMS Diagnostic Tester Tool

 

All process data, all cell voltages, all cell temperatures, the DC current, SOC, SOH and power prediction can be read via CAN interface to the PMS Diagnostic Tester tool and/or to other tester tools. For test purposes process data can be forced.

 

The functional safety is a result of a thoroughly self diagnosis, which tests in short intervals all parts of the battery. The action matrix window of PMS Battery Control makes it very easy to determine, how the battery shall react on each detected error. When the self diagnosis has detected aged components as aged cells and relays a respecting message will be sent to the diagnostic tool and a service hint will pop up on the car display. In this way used up parts can be replaced before they can do any harm.

 

In periods of longer inactivity the battery is going into a sleep mode to save energy. Every 10 minutes the battery is waking itself up and making a complete self diagnosis cycle, before going to sleep again. Certain process data and the DTC are stored in the non volatile memory (EEPROM) while the battery is asleep.

 

The above shown PMS AutoSAR Tester tool imports a test specification, which is written in MS-Word or in MS-Excel. Macros in the test specification can be written in the popular Visual Basic language. It makes long term test sessions possible by directly running the macros in the test specification. The test results (passed/failed) are directly entered in the test specification, so that the test specification, the test data (debouncing, delays, ect) and the test result is all in the same document.

 

The error memory is a professional DTC storage, designed to fulfil the safety standards as defined in ISO26262 and AutoSAR. The development process is optimised for Spice.