BMS HIL Tester for Electric Vehicle Batteries

Challenges

• Frequent ECU software updates put immense pressure on validation teams to update and deploy test software in very short time frames.
• The system needed to be compatible with Hyundai AutoEver’s proprietary xStudio automation software and provide “last-mile” hardware validation.

Objectives

• The main goal was to lower overall expenses, automate processes to eliminate human error, and close the gap between hardware and virtual testing.

Konrad Technologies implemented the KT BMS Tester, a high-reliability hardware solution integrated with Techways.

Functions:

• Cell monitoring (Voltage, Current, Temp)
• State estimation (SoC, SoH, SoP)
• Safety protection (Short circuit, Over/Under-limits)
• Cell balancing and fault logging
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Hardware:

• ‍‍PXI-based measurement, 192-cell simulators (0-5V), and isolation registers (20kΩ – 5.1MΩ)
  

Software:

• Network simulation and Hyundai AutoEver’s xStudio for automation

Applied test procedures:

• ‍‍Hardware-in-the-Loop (HIL) simulation
• Fault injection (FIU)
• Manual validation via a dedicated UI

Challenges during implementation and solution:

‍The transition to Software Defined Vehicle (SDV) testing required complex integration of virtual and physical nodes, resolved through seamless “plug-and-play” IO integration with customer network configurations.

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From this solution the customer gained streamlined workflows and the elimination of redundant steps in the test run and deployment process.

Measureable improvement:

• A 50 % reduction in test time, significantly enhancing efficiency and enabling the team to meet demanding ECU validation schedules.
• Openness of the tester platform to integrate solutions from technology partners e.g. Hyundai Autoever and Techways

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Strengths that contributed most to the success of this project:

• Hardware Reliability: Providing a stable platform that reduced system downtime.
• Ecosystem Collaboration: The strategic partnership between Konrad Technologies and Techways (Korean partner) provided localized, high-precision expertise.

Key insights and best practices gained from this project:

• Automation is critical not just for speed, but for maintaining system longevity and reducing human-induced errors in high-voltage environments.

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