System simulation and hardware component in the loop are key steps in the model-based system engineering (MBSE) process that seeks to shorten the development time of advanced powertrain technologies. Battery Component in the Loop (BCIL), also commonly abbreviated as Battery in the Loop (BIL), is an important step in the evaluation of advanced prototype batteries for electrified vehicles. This paper discusses the possible experiments that can be performed with BIL in order to evaluate the battery in a vehicle systems context (battery focused), and to evaluate the vehicle-level impact of different battery scenarios (vehicle focused). The paper then details the numerous steps necessary in the setup of BIL, including system simulation and virtual vehicle development, hardware setup, closed loop control development, and actual battery evaluation in a virtual vehicle environment.BIL was used to evaluate a prototype 48-V battery developed by Samsung SDI. The virtual vehicle was developed in Autonomie, Argonne National Laboratory's vehicle system simulation software. A mean value engine model developed in AMESim was integrated in the virtual vehicle model and targeted to a dSPACE system for BIL evaluation of the real battery pack. The system evaluation of the Samsung SDI battery will be used to describe the BCIL process throughout the paper.

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A novel, multi-disciplinary approach is presented where experiments, system simulation and Computational Fluid Dynamics are combined for the electrical and thermal characterization of an air-cooled battery pack. As a case study, a Formula Student race car is considered and the procedure proposed consists of three steps: (1) experimental characterization of the battery cells under several thermal conditions; (2) thermal and electrical modeling of the battery stack with system simulation; (3) three-dimensional, time-dependent Conjugate Heat Transfer simulation of the whole battery pack to investigate the cooling performance of the chosen design, and to access fundamental quantities of the batteries, such as state of charge, temperature and ohmic heating. Future improvements of the current work are discussed, including the extension to a liquid-cooled design, battery aging consideration and model integration into a full vehicle system model.