System of the Month February 2025: Full-Power BMS Testing, Smarter and Safer Than Ever

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A Full-Power BMS Test System That Redefines Flexibility, Safety, and Real-Time Performance

In the world of electric mobility, Battery Management Systems (BMS) are among the most critical components—and testing them with precision, safety, and flexibility is non-negotiable. That’s why our System of the Month for February 2025 brings all the right tools together in one powerful setup.

This BMS test system combines the best of scalability, performance, and modular safety, engineered to meet the increasing demands of today’s and tomorrow’s high-voltage battery applications.

What’s Inside the System?

This test system is equipped with everything needed for advanced validation of complex BMS architectures:

  • 120 Battery Cell Simulator Channels: Emulates real battery behavior with high accuracy, making it possible to test battery management under full load conditions.

  • Full Fault Simulation (FSU): Includes the ability to simulate electrical faults under controlled conditions to verify error detection and response strategies of the BMS.

  • 24 Channels of Temperature Sensor Emulation (NTC): For simulating over- and under-temperature conditions—ideal for safety and performance stress testing.

  • 2 Channels of Isolation Fault Simulation (RISO): Enables safety testing through accurate emulation of insulation faults.

  • EtherCAT Communication Interface: High-speed, real-time interface for precise control, synchronization, and data acquisition.

  • Safety-Focused ECU Cabinet: Combines safety and efficiency—ensures the DUT is physically inaccessible during testing, with automatic system shutoff when the cabinet is opened. Also enables short wiring distances for minimal signal loss and optimal test conditions.

Spotlight Innovation: The New Flex Case

This system is the first to feature our newly released Flex Case for FSU, RISO, and NTC—a game-changer in modular hardware design.

What makes it so special?

You can freely combine fault simulation, isolation fault testing, and temperature sensor emulation in a single case—scalable and channel-flexible. Need more NTCs? Fewer FSUs? More RISO lines? The Flex Case adapts to your requirements.

This allows test engineers to tailor their test rig to the actual application—without additional racks, extra space, or costly redesigns. The result is a space-saving, clean, and fully modular system, perfectly aligned with the evolving needs of BMS validation environments.

Why This System Stands Out

This is more than just another BMS test system—it’s a powerful, high-precision platform built for high-voltage, high-performance, and high-safety requirements.

  • It’s modular, to scale with your project.

  • It’s safe, to meet even the strictest lab standards.

  • It’s fast, to deliver real-time control and data acquisition with EtherCAT.

  • And it’s smart, offering an innovative hardware concept with the Flex Case to simplify even the most complex test setups.

For Engineers Who Push the Limits

Whether you’re testing BMS functionality in early development or validating final products under fault conditions, this system gives you the tools to test deeply, safely, and efficiently.

If you’re planning your next BMS validation setup—or want to see how our Flex Case concept could bring more flexibility to your lab—we’re here to help.

Let’s talk about your testing challenges and how we can help solve them, one emulated cell at a time.

📩 Get in touch with us today or explore more about our Battery Cell Simulator solutions.