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Fault Insertion Unit

Programmable Multi-Channel Fault Insertion Unit for Cell Failure Emulation 

The 2U rack-mountable fault insertion unit provides up to 36 independent and isolated channels to extend the battery cell simuation with failure insertion capabilities.

This fault insertion unit (FIU) provides an easy-to-use solution to test and validate battery management systems (BMS) under both typical and fault conditions. Each channel enables the generation of short-circuits, cable breakage and reverse polarity at cell level to test any possible failure scenario. Furthermore, cable breakage on the sense lines allows measurement failures to be simulated.


Key Features

  • Failure insertion at cell level
  • Simulation of different failure scenarios: short-circuit, broken wire, reverse polarity
  • Relays with up to 1000 V isolation
  • System isolation up to 1.6 kV
  • Scalable to hundreds of cells
  • Easy to configure with the Speedgoat I/O Blockset
  • Seamless integration with Simulink® and Simscape™
Number of cells per unit Up to 36
Number of cells per rack

Up to 312

Cell-to-Cell isolation 96 V
Cell-to-Communication isolation 1.6 kV
Power requirements

DC Voltage Input: 48 V DC ± 5%    

Communication interface EtherCAT
Channel Failure Emulation  
Failure type, per channel

Emulation of short-circuit, broken wire and reverse polarity on battery cell.

Emulation of broken wire on sense lines.


Relay type

600 V

1000 V optionally available

Dimensions 2U 19” subrack enclosure




Operating temperature 5 °C – 40 °C

Relative humidity

5 to 95%, non-condensing

Standard Compliance  
Compliances CE, CB, FCC, UK CA

EMC: IEC 61326-1

Safety: IEC 61010-1



Item ID Product Name Components
301001 BCE12-0505

12-channel battery cell emulator up to 5 V and 5 A per cell (2U 19” subrack)

301002 BCE12-0605

12-channel battery cell emulator up to 6 V and 5 A per cell (2U 19” subrack)

301003 BCE12-0805

12-channel battery cell emulator up to 8 V and 5 A per cell (2U 19” subrack)

Custom RACK Fully integrated custom rack solution, including cabling


Pricing information
We do not publish pricing information on our website. Upon request by e-mail or phone, we can provide a complete price list covering our entire product portfolio in various currencies. We recommend that you contact us to discuss your specific needs. We can then quickly provide you with a tailored quotation including technical and pricing information.


Included in the Delivery

  • 2U, 19” rack mountable BCE
  • Test models
  • Comprehensive documentation
  • Cabling to real-time target machine or Battery Cell Emulator (BCE)

Common Applications

  • HIL Testing for BMS in combination with the BCE
  • Simulation of electric and thermal battery behavior down to cell level in combination with the BCE
  • Failure simulation and failure insertion

Supported target machine

  • Performance
  • Mobile
  • Baseline
  • Unit

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