The battery management system (BMS) is a core component to ensure the efficient and safe operation of electric vehicles, and the practical evaluation of key BMS functions is thus of great importance. However, the testing of a BMS with actual battery packs suffers from a poor testing repeatability and a long status transition time due to the uncontrollable degradation of battery systems and testing environment variations. In this paper, to overcome this challenge, we propose an efficient BMS testing framework that uses virtual battery packs rather than actual ones, thus enabling a rapid and accurate evaluation of a BMSs key functions. A series-connected virtual battery pack model through leveraging Copula’s method is formulated to capture the dynamics and inconsistency of individual batteries in the pack. The developed lithium iron phosphate model features low computational efforts and is experimentally validated with different dynamical profiles, implying a high-precision virtual battery pack that is capable of reproducing the actual one. Furthermore, this framework includes a closed-loop testing platform, which can provide the state-of-charge/state-of-power references and thus automatically test and evaluate the states of the battery packs estimated from the BMS. Particularly, we consider the initial polarization that often exists in the batteries during the operation to accurately calibrate the available state-of-power benchmark of battery packs in the real world. The performed BMS testing results using the proposed framework illustrate that the tested BMS cannot adapt to the varied operation conditions, thus leading to high state estimation errors, which may result in the over-charge/discharge or over-temperature of the batteries. Therefore, this work highlights the value of effective BMS testing, providing the promising potential to achieve reliability and durability for battery systems.

With the development of technology, high-power lithium-ion batteries are increasingly moving towards high-speed discharge, long-term continuous output, instantaneous high-rate discharge, and miniaturization, and are being gradually developed towards the fields of electric tools, port machinery and robotics. Improving the power performance of batteries can be achieved from multiple dimensions, such as electrochemical systems and battery design. In order to improve the power performance of lithium-ion batteries, this paper proposes design methods from the perspective of electrochemical systems, which include increasing the high-rate discharge capacity and low impedance of the battery. This article also studies the preparation of high-power lithium-ion batteries. This article aims to improve the rate performance of batteries by studying high-performance cathode materials, excellent conductive networks, and high-performance electrolytes. This article successfully screened high-performance cathode materials by comparing the effects of different particle sizes of cathode materials on electrode conductivity and battery internal resistance. By comparing the effects of electrolyte additives under pulse cycling, high-quality electrolyte additive materials were selected. By comparing the effects of different types, contents, and ratios of conductive agents on electrode conductivity, battery internal resistance, high-quality conductive agents, and appropriate ratios were selected. Finally, a 10 Ah cylindrical high-power lithium-ion battery with a specific energy of 110 Wh/kg, pulse discharge specific power of 11.3 kW/kg, an AC internal resistance of ≤0.7 m Ω, a 10C full capacity discharge cycle of over 1700, a 30C full capacity discharge cycle of over 500, and a continuous discharge capacity of 10C–30C, and a pulse discharge capacity of over 100C was prepared.