Battery Management Unit HITL
Led a team of 3 members to design and assemble a 4-layer hardware-in-the-loop PCB to test the 2024 car's Battery Management Unit (BMU).
- Simulates 22 individual signals across the BMU's 4 main subsystems
- Enables off-car hardware and firmware validation
Design
The board generates every input the BMU receives in the car, so any condition or fault can be simulated on demand. The 4 subsystems it covers:
- Shutdown circuit: simulates sensor and switch faults, then checks the BMU response over CAN
- BMS: checks that the isoSPI communication works
- Precharge and discharge: simulates its control and status signals
- HV measurements: simulates bus voltage and current with 12-bit DACs
- Also drives the fans and checks CAN communication
