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SBB Qualification

Embedded hardware HALT & HASS test

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snymanrickert
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21 views3 pages

SBB Qualification

Embedded hardware HALT & HASS test

Uploaded by

snymanrickert
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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Blue Nova Energy (Pty) Ltd

17 Blend Crescent Office : +27(0)21 205 2000


Firgrove Industrial Park E-mail : [email protected]
Cape Town, 7130 Website : www.bluenova.co.za

SBB Qualification
The qualifications of the SBB module comprises a few processes. A HALT process on the electronics, a non-
functional shock test, transportation test and a bench handling test. All testing was performed with the assistance
of Reutech Communications at their facility in New Germany, Durban.

HALT

BMMC v3.5 and CMM v3.5, both of these boards were subjected to a HALT process to identify points of weakness
on the boards and failure mode. Allowing for the ruggedisation of the boards and confirming function during the
operational specifications.

Below is the typical HALT profile that Reutech uses for their applications. In the ideal case, the system under
testing should be confirm at each temperature point and vibration point. To achieve this, for fixed acceleration
points, the temperature is cycled, and the system monitor for any failures or faults. When a fault occurs, the
temperature and acceleration is altered individually to isolate the cause.

Typical HALT Profile


200

150

100

50

0
0 50 100 150 200
-50

-100

-150

Temperature [°C] Acceleration [g]

Figure 1: Typical Reutech HALT Profile

Given during operation the SBB module will not be subjected to functional vibration. Accordingly, a focus was
placed on the temperature cycling at low acceleration and increasing the vibration slower and later. In Figure 2:
HALT Test Performed on the BMMC and CMM v3.5, the HALT cycle applied to the CMM and BMMC v3.5 is shown.
Due to non-fatal functional issues above 90°C, the system was not pushed beyond this point. Special attention
was paid function of the system during the temperature sweep to evaluate all temperature points.

The final battery firmware was used on the system during the testing. Due to the cell operating temperatures, the
system opened the breaker outside of this range.

At each failure point, the temperature and acceleration were adjusted to confirm the cause of the failure mode.
Individual components were heated and cooled with handheld equipment to confirm which component was the
cause of the failure mode.
Page | 1 Directors: Nico de Bruyn | Terry Lawrenson | James Verster
Blue Nova Energy (Pty) Ltd. | Reg No. 1987/001382/07 | VAT no. 408 0149 232
Blue Nova Energy (Pty) Ltd

17 Blend Crescent Office : +27(0)21 205 2000


Firgrove Industrial Park E-mail : [email protected]
Cape Town, 7130 Website : www.bluenova.co.za

HALT Test
120
100
80
60
40
20
0
-20
-40
-60
-80

Temperature [°C] Acceleration [g]

Figure 2: HALT Test Performed on the BMMC and CMM v3.5

The failure modes of the BMMC and CMM v3.5 that were identified during the HALT testing is listed in Table 1:
HALT Testing Failure Modes with the risk and recommendation listed in Table 2: Risk TableTable 2: Risk Table

Table 1: HALT Testing Failure Modes

Failure Condition Fatal Cause Fix Notes


Replace component
Exceeding with improved
optocoupler (6N314) operating Component rating -40°C
Cellcoms error > 90°C No operating rating temperature range to +85°
No BMMC < -40°C No Exceeding FTDI chip Replace component Component rating
Debug (FX230) operating with improved Exceeding operating
rating operating requirement with 25°C,
temperature range low risk.
Inaccurate cell > 90°C No Voltage reference Replace component
measurements and drift (ISL60002). with improved
(exceeding +/- < -30°C Exceeding operating operating Component rating -40°C
15 mV) condition temperature range to +85°
OLED erratic > 50g No Strain on crimped Apply RTV glue to
pins from loom back of connector on
loom to act as strain
relief
Loss of NTC > 55g No CMM P3 Phoenix Secure in place with * Connector dislodged at
measurements sustained* connector dislodge RTV glue 56g without any
intervention of the
whole testing. Replacing
the connector, it
remained in place at 60g
for a period of more
than 5 minutes.

Page | 2 Directors: Nico de Bruyn | Terry Lawrenson | James Verster


Blue Nova Energy (Pty) Ltd. | Reg No. 1987/001382/07 | VAT no. 408 0149 232
Blue Nova Energy (Pty) Ltd

17 Blend Crescent Office : +27(0)21 205 2000


Firgrove Industrial Park E-mail : [email protected]
Cape Town, 7130 Website : www.bluenova.co.za

Table 2: Risk Table

Failure Risk Probability Recommended Action


Low Low None, 20°C outside of operational spec
Cellcoms error
No BMMC Debug Low Low None, 25°C outside of operational spec

Inaccurate cell Low Low None, 20°C outside of operational spec


measurements
OLED erratic Medium Low Apply RTV as strain relief

Loss of NTC measurements Medium- Low Use RTV to secure connector in place
High

Future recommendations

Where certain modules were tested continually, e.g., CAN communication and CMM communication, sensor and
cell sampling; other modules that do not have a running operation, such as the breaker, were only tested during
given the operation of the BMS logic.

For future testing, special FW should be developed and applied on the battery which continual operates the
battery modules which do not typically have a running operation.

Page | 3 Directors: Nico de Bruyn | Terry Lawrenson | James Verster


Blue Nova Energy (Pty) Ltd. | Reg No. 1987/001382/07 | VAT no. 408 0149 232

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