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Battery Management
Introduction
Based on the RapidECU all-domain electronic control development platform, this solution addresses industry pain points such as inaccurate traction battery voltage/current/temperature acquisition, large SOC/SOH estimation errors, inefficient balancing control, difficult high-voltage safety management and poor cell consistency, delivering an integrated Battery Management System (BMS) solution. The solution adopts a distributed architecture of a main-control BMU plus acquisition CSCs, covering the full workflow of cell monitoring, high-voltage insulation detection, charge/discharge power limiting, fault protection and thermal-linkage control. Paired with a full set of proprietary tools — ECUCoder automatic code generation, MeCa calibration software and the SimCar battery-dedicated HIL bench — it supports the AUTOSAR standard and ISO 26262 functional safety, adapts to various battery packs including LFP, NMC and hydrogen energy storage, and covers passenger vehicles, commercial vehicles, construction machinery and energy storage equipment. One hardware platform serves both prototyping and mass production, effectively shortening development cycles and improving battery service life and vehicle high-voltage safety.
Scheme architecture diagram

Four-layer full-stack BMS system architecture

Plain Text
┌───────────────────────────────────────────────────────────────┐
│ Top Development Tool Layer (Full-chain Closed Loop)│
│ ECUCoder code generation | MeCa X calibration tool | 

│ SimCar battery HIL test bench | Cell simulator │

| Bus recorder | EOL BMS production-line test equipment │ ├─────────────────────────────────────────────────────────┤
│ Middleware Software Layer (BMS Control Core)  │
│ Cell voltage/temperature acquisition algorithms  │

| SOC/SOH/SOP estimation engine  │

| Active/passive balancing strategy  │

| HV insulation & contactor-weld detection logic  │

| Charge/discharge power limiting  │

| Thermal management linkage control  │

| UDS diagnostic protocol stack | Graded fault protection  │

| Daisy-chain/CAN communication protocols │

├─────────────────────────────────────────────────────────┤
│ Hardware Layer (BMS Controller Series)   │
│ U3B/U4B vehicle BMS master control unit    │

| CSC cell monitoring module    │

| CVS high-voltage acquisition board    │

| Multi-channel daisy-chain communication interfaces    │

| High-precision voltage/temperature acquisition channels    │

| HV relay drivers, insulation detection hardware, 

  wide-temperature automotive-grade design |├─────────────────────────────────────────────────────────┤
│ Vehicle Application Layer (Battery System Management) │
│ Real-time cell state monitoring  │

| Safe charge/discharge control  │

| Cell balancing control  │

| HV power up/down & precharge management │ 

| Cross-domain coordination with VCU/thermal management  │

| Battery fault diagnostics, warning, and graded protection |└───────────────────────────────────────────────────────────────┘

System interconnection logic

Individual cells / high-voltage circuit sensors → CSC acquisition module (daisy-chain upload) → BMU main control unit. The BMS communicates with the vehicle central domain / VCU via CAN and interfaces with the SimCar battery HIL simulation bench; upper-computer tools complete the full closed loop of modeling, code generation, calibration and automated testing.


Functional Features

1.  High-precision multi-dimensional battery status monitoring
The CSC acquisition module achieves synchronized multi-channel cell voltage and temperature sampling, and together with the CVS high-voltage acquisition unit accurately measures total voltage, charge/discharge current and insulation resistance. With low sampling error, it captures cell voltage and temperature differences in real time.

2. High-precision SOC/SOH/SOP estimation algorithms
 Fusing ampere-hour integration, open-circuit voltage correction and temperature compensation, SOC estimation error is kept within 5%. It supports SOH aging assessment and dynamic SOP peak charge/discharge power limiting to avoid battery damage from over-charging and over-discharging.

3. Dual-mode battery balancing control
Supporting both passive resistor balancing and active energy-transfer balancing, it automatically matches the balancing strategy to battery capacity and usage scenario, quickly narrowing cell voltage differences and extending battery pack cycle life.

4. Full-chain high-voltage safety management
Integrated with pre-charge logic, high-voltage relay welding detection, insulation fault diagnostics and collision-induced high-voltage power-down protection, its tiered fault handling logic quickly cuts off the high-voltage circuit on over-voltage, under-temperature, over-current or insulation failure, safeguarding vehicle safety.

5. Cross-domain coordination and standardized communication
It interacts in real time with the vehicle VCU and thermal management controller via CAN FD, coordinating cooling and heating strategies; supports daisy-chain acquisition and J1939/UDS diagnostic protocols, automatically generates A2L calibration files, and is compatible with mainstream calibration tools such as INCA and MeCa.

6. Dedicated battery HIL full-scenario simulation
The SimCar battery cell simulator and high-voltage fault injection box simulate extreme conditions such as cell short circuits, wire breaks, insulation failures and high/low temperatures, automatically executing tens of thousands of charge/discharge test cases and greatly reducing real-pack test risks.


Advantages of the plan

1. Same-source software and hardware, greatly shortening development cycles. 

Prototyping and mass-production BMS hardware are fully interchangeable; ECUCoder generates vehicle-level BMS code with one click, eliminating manual low-level driver development. The development cycle is shortened by 50% compared with traditional approaches.

2. Fully self-controlled toolchain with no foreign tool lock-in.

 Modeling, code generation, HIL simulation and calibration software are all developed in-house, with fully open low-level code and support for domestic MCU chips — no expensive overseas licensing fees.

3. Distributed architecture adaptable to all battery packs. 

The modular BMU+CSC design flexibly scales the number of cell strings, suiting small-capacity passenger-vehicle batteries and large-capacity commercial-vehicle energy storage batteries. Hardware can be flexibly trimmed for both small/medium and large batch production.

4. Complete high-voltage safety system meeting functional safety. 

With comprehensive FMEA analysis and fault-injection simulation capability, it meets ISO 26262 functional safety requirements, covering the full safety flow of low-voltage wake-up, pre-charge and collision power-down, and passes stringent DV/PV automotive-grade tests.

5. Full-lifecycle battery data traceability. 

Driving charge/discharge data and fault logs can be stored; production-line EOL equipment performs fully automated off-line calibration, flashing and functional testing of the BMS, and production data can interface with MES systems.

6. Wide multi-scenario adaptability. 

Covering battery-electric passenger vehicles, hybrid models, fuel-cell support battery systems, heavy-truck energy storage, construction machinery battery packs and stationary energy storage stations, with strong universality.


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