Testing Energy Storage Systems: From EVs to Utility Grid

Agenda Energy storage system landscape Electric vehicle battery simulation Utility grid storage performance testing

Bloomy Controls, Inc. Founded in 1992 NI Select Alliance Partner Turnkey system development 16 Certified LabVIEW Architects Offices: Windsor, CT Marlborough, MA Fairlawn, NJ

Bloomy Controls Energy Focus Provide test and data acquisition products to battery, grid storage, and ground transportation companies 3

Bloomy Controls Energy Focus Battery Packs Battery Management System (BMS) Battery Simulation / HIL Battery Chargers Utility Grid Energy Storage Systems R&D Characterization Life cycle testing Functional Test End of Line 4

Energy storage system landscape

Energy Storage Systems (ESS) Chemical Biological Electrochemical Electrical Bloomy Controls Focus Batteries Fuel cells Capacitors Superconductors Mechanical Thermal Types of Energy Storage Systems 6

Batteries: Capacity Range Pacemaker Batteries 250W Electric Vehicle Batteries 200kW Grid Storage Systems 2MW 7

Global HEV / EV Projections 8

Grid Energy Storage Growth Source: NanoMarkets' forecast for principal battery classes over the next eight years 9

Smart Grid: Energy Storage Grid Energy Storage Smart grid stabilization system Vehicle to Grid 10

ESS Components: Electric Vehicle Electric Vehicle ESS (battery) Battery Management System Module 1 Module 2 Module X Safety Auxiliaries 11

ESS Components: Utility Grid Utility Grid Energy Storage Control System BMS 1 BMS 2 BMS x Inverters Auxiliary Safety Thermal Mod. 1 Mod. 2 Mod. x 12

ESS Testing Challenges High Power Isolation Monitoring high voltages (EV: ~700VDC, Grid: > 1000VDC) Monitoring high currents (Grid: ~ 2000ADC) Noise Ensure accurate measurements Reduce frequency injections Increase signal to noise ratio Synchronization Accurate power and energy calculations Ensure performance correlation 13

Electric vehicle battery simulation

Battery HIL Simulation System United States Army Tank and Automotive Research, Development, and Engineering Center Provide a battery HIL system for the evaluation of battery management systems for hybrid tanks. 15

HIL system to BMS connections Battery Management System (BMS) 600V pack: Up to 170 Series / Parallel stacked cells Monitor & balance Over voltage Under voltage Inrush current Temperatures Safety Interlocks Fault Conditions CAN Serial, etc. 600VDC 0.0 5.0V 10kΩ 2MΩ 24V DIO 100mS timing Custom protocols 16 GND Cell simulators Battery HIL

Battery HIL Simulation: System 17

Cell Simulation: Challenges Emulation of 176 independent cells 0-5V, 0.5mV resolution, ±0.1% accuracy 0-250mA, 0.2mA resolution, ±1% accuracy Flexible series / parallel stack connections 750V channel-to-channel isolation 750V channel-to-ground isolation Cell Measurements High common mode voltages Thermal management Require space for air flow Batteries are inherently isolated Control 5V 5V 5V 5V 600V 595V 15V 10V 5V 0V Common mode voltage 18

Cell Simulation: Implementation Isolation Output: Utilize high accuracy DC/DC converter and ensure cell calibration can be performed Measurement: Use opto-isolators and high CMRR amplifiers Channel-to-channel: Ensure you meet the creepageand clearance tolerances 19

Utility grid energy storage performance testing

Grid Storage Near-term Applications Load leveling and power quality systems to protect from brief power interruptions Frequency regulation and stability for variability of renewable energy sources Peak shaving to help manage electricity costs under variable utility tariffs 1200 1000 Demand Limit Output ESS power 800 600 400 21 200 0

Grid Storage Performance Testing Requirements Test 25kW to 2MW systems 200+ mixed signal acquisition channels Evaluate performance for application-specific operations cycles Analyze data and generate industry reports

Grid Storage Performance Testing Lab Step Down Transformer Power Conversion System Aux Power Panel Utility Voltage Source Simulation Application Control Simulation ESS Control & Data Acquisition System Master Controller Battery Management System Thermal Management Battery Racks Example Tests Interconnect tests Startup / Shutdown / E-Stop Equipment failure Abnormal Grid Events Performance testing Power Rating Energy Rating Round trip efficiency Short / Long term test Application testing Frequency Regulation Peak Shaving Wind Farm Smoothing 23

Grid Storage: Test System Challenges Configurable System must accommodate many unique Energy Storage Systems with diverse connections and requirements High signal count Systems must measure multiple AC /DC voltages and currents, temperatures, flow, communications, etc. High power Distributed and synchronous Data management and reporting Up to 800VAC, 1200VDC Up to 2000A System needs to connect to all ESS components in a trailer All AC signals need to be synchronous (24+ channels) System must analyze power, energy, and other parameters Industry standard reports must be generate 24

Grid Storage: General Signals Parameter Name Channels Max Value Sampling Rate (Hz) Accuracy AC Voltage 12 1200V 20.0k ±0.5% AC Current 12 2000A 20.0k ±0.5% DC Voltage 6 1200V 3.0k ±0.5% DC Current 6 2000A 3.0k ±0.5% DC Cell Voltages 96 14V 10 ±0.3% Cell Temperatures 32 60 ºC 10 ±1.0% Airflow 2 6000fpm 10 ±1.0% Communications 2 CAN, Modbus, Ethernet Power quality measurements: NEN-EN-IEC 61000-4-30 Monitoring electric power quality: IEEE Std 1159-2009 Distributed power resources: IEEE Std 1547.1-2005 25

Grid Storage: Test System Overview 3 distributed containers with PXI RT chassis Low level signals with isolation transducers One amazing piece of software 26

NI PXI hardware with isolation Use highly accurate, synchronous data acquisition cards with isolation transducers Tip: No synch? Compensate in analysis PXI ±400mA ±500mA Tip: Transducers = Isolation 27

Grid Storage: Signal Integrity Build Intelligent Cables to identify signal type Utilize twisted pair, shielded cables Select isolation transducers with current output Tip: Shield 28

Grid Storage: Highly Configurable

Grid Storage: Data Analysis Voltage and Current Three Phase RMS (V & I) Total Harmonic Distortion Frequency Oscillation Power and Energy Three Phase or Total Power Power Factor Active Power Apparent Power Reactive Power Energy Active Total Energy Apparent Total Energy Reactive Total Power Quality Over voltage and under voltage Over current Three Phase Voltage Harmonics 30

Wrap-up ISOLATION ISOLATION ISOLATION Pay special attention to the acquisition hardware High voltage / current can work with PXI using the correct isolation transducers Use DIAdem when analyzing large amounts of data 31

Jonathan Murray info@bloomy.com 508-281-8288 bloomy.com