Hardware Overview

The Battery Test System hardware comprises the BTS-16101 measurement rack, optional FieldDAQ devices for in-chamber measurements, and third-party equipment integration for battery cyclers, thermal chambers, and chillers.

BTS-16101 Measurement Rack Components

The BTS-16101 measurement rack is a low power ATE-116H-A 24U rack modified specifically for use in testing automotive electric batteries.

The BTS-16101 is designed for modularity and expansion and may include a combination of the following components depending on your specific test application needs.

Table 1. BTS-16101 Required Components
Component Type Quantity Part Description
Measurement Rack 1 RMX-10011 Custom ATE Core Configurations assembly, low power 24U with included:
  • Emergency power off (EPO) panel
  • Power entry panel (PEP)
  • Remote EPO connector
  • Power distribution unit (PDU)
  • Uninterruptible power supply (UPS)
Controller 1 cRIO-9047 1.60 GHz Quad-Core CPU, 4 GB Storage, -40 °C to 70 °C, Kintex-7 70T FPGA, 8-Slot CompactRIO Controller
Ethernet Switch Up to 2 cRIO-9805 4-port 802.1AS Time-Sensitive Networking (TSN) Ethernet Switch Expansion Module for CompactRIO
1 EDS-316-T MOXA 16-port Industrial Unmanaged Ethernet Switch
Power Supplies Up to 12 RMX-4101 210 W, 60 V, 3.5 A, Programmable Power Supply
CAN/LIN 1 or more NI-9860 2-port, C Series Vehicle Multiprotocol Interface Module
Analog Input Voltage Module 1 or more NI-9224 8-channel, ±10 V, 1 kS/s/ch, 24-Bit, Simultaneous Input, C Series Voltage Input Module
NI-9225 3-channel, 300 V RMS, 50 kS/s/ch, 24-Bit, Simultaneous Input, C Series Voltage Input Module
NI-9228 8-channel, ±60 V, 1 kS/s/ch, 24-Bit, Simultaneous Input, C Series Voltage Input Module
Table 2. BTS-16101 Optional Components
Component Type Part Description
CompactDAQ cDAQ-9189 8-Slot, TSN-Enabled Ethernet CompactDAQ Chassis
GPIB/RS-232 GPIB-RS232 Serial, RS232 GPIB Instrument Control Device
RS-232 NI-9870 4-Port, RS232 C Series Serial Interface Module
NI-XNET CAN/LIN Transceiver Cable TRC-8543 CAN High-Speed/Flexible–Data Rate or Low-Speed/Fault-Tolerant Transceiver Cable
TRC-8546 LIN Transceiver Cable
Thermocouple NI-9212 8-Channel, 95 S/s/ch Simultaneous, ±78 mV, C Series Temperature Input Module
NI-9213 16-Channel, 75 S/s Aggregate, ±78 mV, C Series Temperature Input Module
HVIL Control: SPST Relay NI-9482 4-Channel, 60 V DC (1 A)/250 V AC (1.5 A), C Series Relay Output Module
HVIL Monitor: AI Current NI-9227 4-Channel, 50 kS/s/ch, 5 A RMS, 24-Bit, C Series Current Input Module
HVIL Monitor: Digital Input NI-9422 8-Channel (Sinking/Sourcing Input), 24 V to 60 V, 250 µs, C Series Digital Module
HVIL Monitor: PWM Input NI-9423 8-Channel (Sinking Input), 24 V, 1 µs, C Series Digital Module
NI-9437 8-Channel (Sinking Input), 24 V DC to 250 V DC, 1 µs, C Series Digital Module
Digital Input NI-9375 32-Channel (Sinking Input, Sourcing Output), 30 V, 7 µs (Input)/500 µs (Output), C Series Digital Module
Digital Output NI-9475 8-Channel (Sourcing Output), 60 V, 1 µs, C Series Digital Module

Battery Cyclers

The Battery Test System integrates with various battery cyclers from NI and third parties. Refer to the user manual for your cycler for interfacing options. Refer to your integrator for detailed instructions on how to add and configure a battery cycler custom device.

Third-Party Equipment Integration

To further control your test environment, use the following instruments in the measurement rack to integrate and communicate with third-party battery cyclers, thermal chambers, and chillers.

  • NI-9870 C Series Serial Interface Module—Adds RS232 or RS485/RS422 serial ports to CompactRIO systems.
  • NI-9860 C Series Vehicle Multiprotocol Interface Module—Provides a hardware-selectable controller area network (CAN) and/or local interconnect network (LIN) interface for developing applications with the NI-XNET driver on CompactDAQ or CompactRIO. The NI-XNET platform includes a series of high-performance CAN and LIN interfaces that you can use to communicate with hardware using those protocols. NI-XNET is used to communicate with the battery management system and CAN-based instruments, some third party battery cyclers, chillers, and environmental chambers.
  • GPIB-RS232 GPIB Instrument Control Device—Provides GPIB/serial communication to third-party instrument depending on the measurement rack configuration.

FieldDAQ Hardware for In-Chamber Measurements

You can use the FD-11613 (8-channel) or FD-11614 (16-channel) Temperature Input Devices for FieldDAQ to move instrumentation inside the thermal chamber, reduce cabling, and accelerate test setup. The FieldDAQ devices are external components to the BTS-16101 measurement rack.