System of the Month November 2025: high-voltage BMS validation for 800 V systems
Project report from November 2025: a 216-cell Battery Cell Simulator system for battery management system (BMS) validation in an 800 V vehicle architecture.
The configuration
- 216 simulated cells
- NTC/PTC temperature simulation
- Isolation testing and fault insertion
- Integrated BMU and CMC drawers
The engineering task
The customer is developing a BMS for a vehicle architecture with around 200 cells and an 800 V context. The test setup must bring cell signals, sensing and control-unit integration together.
The delivered system
A Fault Simulation Unit provides fault insertion. Dedicated drawers integrate the battery management unit (BMU) and cell monitoring controllers (CMC).
Room for the next stage
The cabinet reserves space for planned real-time PC and I/O integration, including ADC acquisition. These are expansion provisions; they are not presented as already installed functions.