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System of the MonthDecember 2024

System of the Month December 2024: 72-cell Battery Cell Simulator

A 72-cell configuration combines temperature-sensor emulation, real-time fault simulation and CAN or EtherCAT control.

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System of the Month December 2024: 72-cell Battery Cell Simulator
QuestionStart with the engineering problem
ContextConnect application, standard and product
SourceIdentify document and publication status
Next stepContinue to current technical scope
Test scenario: Illustrative test: one low cell voltage

Set the relevant simulated cell below the controller’s specified threshold and inspect the BMS measurement and diagnostic response. The other cell channels can remain at their normal inputs. Control interfaces connect this sequence to the surrounding test system; the article’s 72-cell configuration describes the published project.

A compact BMS (battery management system) project still needs deterministic control over every relevant cell and sensor input.

At a glance

  • 72 emulated cells
  • Temperature-sensor emulation
  • Real-time fault simulation
  • CAN and EtherCAT control

Why this mattered

Using real cells for threshold and fault testing introduces variation, limited repeatability and avoidable safety constraints.

The system approach

The featured simulator provides 72 cell channels, temperature-sensor emulation and real-time fault control through CAN and EtherCAT interfaces.

What the project shows

The system gives the customer a repeatable platform for measurement, diagnostics and protection testing without depending on battery-cell behaviour.

Related reading

Continue through the archive.

Related entries retain the publication date and lead to the current technical route.

System of the MonthDecember 2025

System of the Month December 2025: EVCA Multi Mobile for interoperability in the field

EVCA Multi Mobile places synchronised communication, power and timing analysis between a real EV and a real charging station.

System of the MonthNovember 2025

System of the Month November 2025: high-voltage BMS validation for 800 V systems

A 216-cell test system combines cell simulation, isolation testing, electrical fault insertion and integrated rack design.

System of the MonthOctober 2025

System of the Month October 2025: EVCA testing according to IEC 61851-23 Annex CC

The configuration addresses real-world DC fast-charging robustness with controlled short-circuit, load-dump and insulation-fault scenarios.

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Turn the information into the next engineering decision.

Continue to the relevant application, current product scope or responsible comemso team.

Configure your test systemContact application engineering