DS5486 Temperature Simulation Board

High-end board for emulating resistor-based temperature sensors at cell level

The high-precision DS5486 Temperature Simulation Board is an eight-channel SCALEXIO board for hardware-in-the-loop (HIL) testing of cutting-edge battery management systems (BMS) on the voltage level.​​​​​​​ It enables the emulation of temperature sensors at cell level for system voltages of up to 1,500 V and comes with integrated electrical failure simulation. The board can be used for a wide range of BMS use cases across different industries – from battery electric vehicles to stationary storage systems.

The DS5486 consists of two separate modules: the actual temperature simulation module and the auxiliary module.

High-voltage (HV) batteries used in electric vehicles and other energy storage applications must be operated within a certain temperature range. To prevent a battery from overheating, it is important to measure and control its temperature. This extends the battery life and increases its safety.

A battery is therefore equipped with several sensors which measure local temperatures. The DS5486 simulates these temperature sensors with high precision.

Depending on the simulated battery type and test focus, several boards can be combined in one or more 19" slot units within a SCALEXIO Battery HIL system. The boards are controlled by a dynamic thermal battery simulation model running on the HIL system.

The boards emulate the resistances of up to eight typical temperature sensors within the range of 20 Ω to 1 MΩ. This relatively wide range means that all usual negative and positive temperature coefficient (NTC and PTC) sensors can be emulated for a wide temperature range. Sensor emulation is performed at a resolution of 19 bits with high dynamic accuracy.

Thanks to the fast and low-latency IOCNET connection to the SCALEXIO real-time system, updating the resistor values of all boards takes less than 200 µs.

Technical Details

Parameter
Specification1)

Hardware structure
  • 2 sensor groups per board with 4 sensors each
  • 128 sensors per slot unit

Sensor resistance range
  • 20 Ω … 1 MΩ

Sensor programming resolution
  • 19-bit

Precision

(for positive sensor voltages and depending

on the adjusted resistance value)
  • ±(0.2% + 0.1 Ω) for 20 Ω … 3.9 kΩ
  • ±0.5% for 3.9 kΩ … 19 kΩ
  • ±1% for 19 kΩ … 31 kΩ
  • ±2% for 31 kΩ … 100 kΩ
  • ±3% for 100 kΩ … 250 kΩ
  • ±20% for 250 kΩ … 1 MΩ

Maximum sensor voltage
  • 8 V

Maximum sensor power dissipation
  • 0.25 W
Isolation
  • 1,500 V between the sensors and the environment
  • 1,500 V between sensor groups
  • 90 V between the sensors of a group
Connection
  • IOCNET interface to the SCALEXIO real-time system
Maximum update rate for all sensors
  • 5.6 kHz (processor)
Failure simulation
  • Broken wire between ECU and sensor (400 MΩ typ.)
  • Short circuit of sensor (1 Ω typ.)

1) Preliminary data. For technical specifications, please contact dSPACE.

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