Battery Cell Simulator
Battery cell simulation up to 300 cells for developing and validating Battery Management Systems (BMS).
Overview
The Battery Cell Simulator (BCS) is a hardware-in-the-loop system for developing, validating and production-testing Battery Management Systems (BMS). It replaces real cells with parameterisable virtual cells for safe, reproducible laboratory testing — up to 300 cells per system (up to 1500 V total), with 0.5 mV voltage measurement precision and CAN / EtherCAT / USB interfaces.
Key Features
Up to 300 Virtual Cells
Independently parameterisable electrical characteristics per cell
Comprehensive Fault Injection
Simulates disconnections, short circuits, reverse polarity and sensor failures
High-Precision Measurement
0.5 mV standard voltage precision for R&D and EOL applications
Isolated Temperature Emulation
Galvanically isolated NTC / PTC thermistor emulation for thermal validation
High-Frequency Coulomb Measurement
Measures every 100 μs (50 ms interval with 500 integrated values)
Multi-Protocol Connectivity
CAN (unlimited cells), EtherCAT (up to 120 cells, μs cycles) and USB
Capabilities
Develops and verifies BMS cell monitoring controllers (CMC)
Validates State of Charge (SoC) and State of Health (SoH) algorithms
Tests both passive and active balancing algorithms
Measures quiescent / leakage current at μA levels during BMS deactivation
Tests BMS-to-EVCC (Electric Vehicle Charge Controller) communication
Climate-chamber-compatible for multiplexed temperature testing
MATLAB / Simulink integration for dynamic battery modelling
Key Specifications
| System Voltage | Up to 1000 V (200 cells × 5 V) |
| Cell Voltage Precision | 0.5 mV (standard) / 1.45 mV (BCS simulation) |
| Balancing Current | Up to 6.5 A per cell |
| Coulomb Measurement | Every 100 μs (50 ms interval / 500 integrated values) |
| Cell Count | 12 - 36 (portable), 24 - 60 (mid-range), 204+ (custom / EOL) |
| Interfaces | CAN (unlimited cells), EtherCAT (up to 120 cells), USB |
| Software | comemso Toolbox with MATLAB / Simulink integration |
| Fault Simulation | Disconnection, short circuit, reverse polarity, sensor failure |
| EMC | Regularly tested in manufacturer's in-house EMC chamber |
| Recalibration | Annual recalibration recommended (factory / on-site / SmartCal) |
Interested in this product?
Contact our team for more information and a quotation.