Abstract:We have developed a battery hardware-in-the-loop (HIL) setup, which can facilitate the process of design and evaluation of power management controllers for hybrid electric vehicles (HEVs) in a novel cost-and time-effective manner. Since the dynamics of the battery greatly affects the HEV power management controller design, and because such dynamic behavior is difficult to model, physical batteries and a real-time battery cycler are included in the setup for greater simulation fidelity. The setup employs a scaled-down battery HIL that reduces the development and testing efforts, while, by using Buckingham's Pi Theorem, maintains the required flexibility and enhances the control loop fidelity.In this article, the application of the setup in integrating the development and the evaluation processes is shown. First, the setup is used for parameter identification of a simple control-oriented model of the battery, which is then used in the power management controller design. Finally, the real-time performance of the designed controller, programmed into an electronic control unit (ECU), is tested with the same setup in the realistic control environment. Furthermore, the battery HIL simulation results show that the designed controller is able to accurately capture the dynamics of the real system, by which the assumptions made in its design process can be confidently justified.