Development of a Battery Cell Emulator for Hardware-in-the-Loop Systems

As the demand for electric vehicles and renewable energy systems continues to rise, the need for efficient battery testing methodologies becomes increasingly crucial. Hardware-in-the-Loop (HIL) systems have emerged as powerful tools for validating the performance and control strategies of battery management systems (BMS). However, the integration of actual battery cells into HIL setups presents significant challenges due to safety concerns, cost, and limited availability of high-power battery packs. The goal of this thesis is to face this challenge by proposing the development of a Battery Cell Emulator (BCE) specifically tailored for HIL applications. The research begins with a thorough analysis of battery cell characteristics, including voltage-current profiles, state-of-charge behavior, and impedance spectra. A study was conducted in depth on a possible equivalent circuit that would allow reproducing the internal dynamics of a real cell and its parameters. Based on this analysis, a mathematical model of battery behavior is formulated, capturing the essential dynamics of cell operation. Using this model, a real-time emulation platform is designed and implemented, capable of replicating the behavior of various battery chemistries and configurations. The platform utilizes advanced control algorithms to ensure accurate emulation of transient responses and dynamic operating conditions. To validate the effectiveness of the proposed BCE, extensive experimental studies are conducted using a real-time simulator from dSpace company, made available by Kineton s.r.l., during an entire charge-discharge cycle of a battery cell. The results demonstrate that the emulator accurately reproduces the behavior of actual battery cells across a wide range of operating conditions, enabling comprehensive testing of BCE functionality for BMS future applications in a safe and cost-effective manner. Overall, this thesis contributes to the advancement of HIL testing methodologies by providing a practical solution for battery emulation, thereby facilitating the rapid development and deployment of next-generation BMS technologies for electric vehicles and renewable energy systems.