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Temperature Sensor Emulator With Fault Insertion Unit

High-precision and Isolated Emulation of Temperature Sensors With Programmable Multi-Channel Fault Insertion Unit for Cell Failure Emulation

The unified Temperature Sensor Emulator (TSE) with Fault Insertion Unit (FIU) allows you to test your battery management system (BMS) under varying thermal conditions for typical and fault scenarios. This enables you to emulate cell-level faults such as short circuits, broken cables, and reverse polarity scenarios, and faults between cells and broken wire connections to the cell monitoring unit in the BMS in temperatures with resistances up to 4 MΩ. Providing the necessary channel-to-system isolation levels of 1kV for your tests, this unit protects your entire testing environment, avoiding unwanted interactions between different testing components, and allows you to test your controllers safely.

The 2U rack-mountable unit provides up to 36 independent and isolated channels, with up to 24 channels for the FIU and up to 12 for the TSE.

The unified TSE with FIU is an ideal extension to the Speedgoat Battery Cell Emulator (BCE). It can be easily integrated into a rack system, making it ideal for large-scale HIL testing with thousands of I/O signals.

 

Key Features

  • Programmable resistor chain with a range up to 4 MΩ, adjustable in 1 Ω steps, and accuracy of 0.1 % ± 500 mΩ across the entire range of values
  • Fault insertion at the cell level; emulation of various fault scenarios: short circuit, reverse polarity, broken wire at the cell level and in connection to the BMS
  • Plug-and-play compatibility with the Battery Cell Emulator unit
  • Modular unit with up to 24 battery cell fault insertion channels along with up to 12 temperature sensor channels in one single unit
  • Channel-to-system isolation up to 1 kV
  • Channel-to-channel isolation up to 100 V
  • Easy to configure with the Speedgoat I/O Blockset
  • Seamless integration with Simulink® and Simscape™
General  
Number of channels per unit 16, 32, or 36
Number of channels in series 252
Channel-to-channel isolation 100 V
Channel-to-system isolation 1 kV
Power supply

DC Voltage Input: 48 V DC ± 5%    

Power consumption

40 W max. for four channels
An additional 25 W for each subsequent set of 12 channels

Communication interface EtherCAT
Channel Fault Emulation  
Failure type, per channel

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

Emulation of broken wire to BMS

Temperature Emulation Characteristics  
Resistor range 10 Ω to 4 MΩ
Resolution 1 Ω
Accuracy ±0.1 % ± 0.5 Ω
Integrated fault insertion Emulation of open circuits and short circuits (50 mΩ)
Power Max. 100 mW per channel
Current Max. 10 mA
Voltage Max. 20 V
Settling time Max. 10 ms
Physical
 
Dimensions 2U 19” subrack enclosure, depth: 350 mm
Connectors

2x RJ45 connectors for communication with the real-time target machine, as well as additional Battery Cell Emulators, Fault Insertion Units, and Temperature Sensor Emulators

16 x, 32 x, or 36 x 4-pin Mega-Fit input/output connectors (Molex part No. 768250004)

1 x 5-pin pluggable MSTB terminal block for Power Input and INTERLOCK (Phoenix part No. 1776728)

Refer to order information for the correct item ID depending on the number of channels

Weight

-

Environmental
 
Operating temperature 5 °C to 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

RoHS, REACH

 
 
 
 

Item ID Product Name Components
301051 FIU12-1/TSE04-1000-1 12-channel Fault Insertion Unit and 4-channel Temperature Sensor Emulator (2U 19” subrack)
301052 FIU24-1/TSE08-1000-1 24-channel Fault Insertion Unit and 8-channel Temperature Sensor Emulator (2U 19” subrack)
301053 FIU24-1/TSE12-1000-1 24-channel Fault Insertion Unit and 12-channel Temperature Sensor Emulator (2U 19” subrack)

 

Optional Accessories
30100Z BCE/FIU Cable and Terminal Board Kit
  • 12 x 4-pin Mega-Fit cables
  • 1 x terminal board
  • Compatible with Battery Cell Emulator (BCE) and Fault Insertion Unit (FIU)
30104Z TSE Cable and Terminal Board Kit
  • 4 x 4-pin Mega-Fit cables
  • 1 x terminal board
  • Compatible with Temperature Sensor Emulator (TSE)

 

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 Temperature Sensor Emulator (TSE) + Fault Insertion Unit (FIU)
  • Test models
  • Comprehensive documentation

Common Applications

  • HIL Testing for BMS in combination with the Speedgoat Battery Cell Emulator (BCE)
  • Emulation of thermal battery behavior down to cell level
  • Emulation of various temperature sensors, such as NTC, and PTC types
  • Fault Insertion down to cell level

Supported target machine

It requires one available Ethernet port supporting EtherCAT. Multiple units, including BCEs and FIUs, can be connected in a daisy chain.

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