Developing a Model-in-the-Loop Testbench for Battery Management Systems: Advancing Test Methodologies for State-of-X Estimation

Lithium-ion battery systems require robust BMS for safety and reliability. Extensive BMS testing presents challenges like safety risks, long testing times, and variability. To address these issues and expedite development, a testing methodology based on X-in-the-Loop (XiL) paradigms is proposed. This methodology ensures comprehensive validation and cost reduction. Using MathWorks Simulink and Simscape Batteries, a virtual testbench is developed to model both the BMS and the battery pack. The BMS includes virtualized master and slave units, emulating sensor behavior and SoC estimation algorithms. A virtual battery cycler enables specific current profile testing. As case study, this setup benchmarks SoC estimation algorithms at MiL and SiL levels, with potential HiL expansion for real BMS device validation, enhancing testing capabilities and automating procedures for safer, faster BMS development.