hitl_tester.test_cases.bms.test_2590_assembly

  1"""
  2| Test                 | Confirm assembly mode transition |
  3| :------------------- | :---------------------------------- |
  4| GitHub Issue         | #232 (battery-benchtop-rev1)        |
  5| Description          | To ensure a successful bringup, the firmware starts with \
  6                         undervoltage, cell imbalance, and temperature faults disabled. \
  7                         This test confirms that's the case and checks that the faults \
  8                         can be enabled and function. |
  9"""
 10
 11from __future__ import annotations
 12
 13import time
 14
 15import pytest
 16
 17from hitl_tester.modules.bms.bms_hw import BMSHardware
 18from hitl_tester.modules.bms.event_watcher import SerialWatcher
 19from hitl_tester.modules.bms.plateset import Plateset
 20from hitl_tester.modules.logger import logger
 21
 22CELL_VOLTAGE = 3.8
 23
 24bms_hardware = BMSHardware(pytest.flags)  # type: ignore[arg-type]
 25bms_hardware.init()
 26
 27serial_watcher = SerialWatcher()
 28plateset = Plateset()
 29
 30
 31def reset_cell_sims():
 32    """Activate cell sims and set appropriate temperatures."""
 33    logger.write_info_to_report("Powering down cell sims")
 34    for cell in bms_hardware.cells.values():
 35        cell.disengage_safety_protocols = True
 36        cell.volts = 0.0001
 37    time.sleep(5)
 38    logger.write_info_to_report("Powering up cell sims")
 39    for cell in bms_hardware.cells.values():
 40        cell.volts = CELL_VOLTAGE
 41        cell.disengage_safety_protocols = False
 42    for cell in bms_hardware.cells.values():
 43        cell.exact_volts = CELL_VOLTAGE
 44    logger.write_info_to_report("Setting temperature to 15°C")
 45    plateset.thermistor1 = 15
 46    plateset.thermistor2 = 15
 47
 48
 49def test_no_overtemp_faults():
 50    """
 51    | Requirement          | Confirm overtemp flags are disabled |
 52    | :------------------- | :---------------------------------- |
 53    | GitHub Issue         | #232 (BMS)                          |
 54    | Instructions         | 1. Rest at 60°C and ensure no fault is raised </br>\
 55                             2. Discharge at 100mA, 60°C and ensure no fault is raised </br>\
 56                             3. Charge at 100mA, 46°C and ensure no fault is raised </br>\
 57                             4. Rest at 94°C and ensure no permanentdisable is raised |
 58    | Pass / Fail Criteria | Fail if a fault is raised |
 59    """
 60    logger.write_info_to_report("Testing Overtemp")
 61    reset_cell_sims()
 62    serial_watcher.start()
 63
 64    # Test resting overtemp
 65    logger.write_info_to_report("Resting at 59°C")
 66    plateset.thermistor1 = 60
 67    serial_watcher.assert_false("flags.prefault_overtemp_discharge", True)
 68    serial_watcher.assert_false("flags.fault_overtemp_discharge", True)
 69
 70    # Test discharging overtemp
 71    logger.write_info_to_report("Discharging at -100 mA, 59°C")
 72    bms_hardware.load.mode_cc()
 73    bms_hardware.load.amps = 0.100
 74    bms_hardware.load.enable()
 75    serial_watcher.assert_false("flags.prefault_overtemp_discharge", True)
 76    serial_watcher.assert_false("flags.fault_overtemp_discharge", True)
 77    bms_hardware.load.disable()
 78
 79    # Test charging overtemp
 80    logger.write_info_to_report("Charging at 100 mA, 46°C")
 81    bms_hardware.charger.set_profile(16.8, 0.1)
 82    plateset.ce_switch = True
 83    bms_hardware.charger.enable()
 84    plateset.thermistor1 = 46
 85    serial_watcher.assert_false("flags.prefault_overtemp_charge", True)
 86    serial_watcher.assert_false("flags.fault_overtemp_charge", True)
 87    bms_hardware.charger.disable()
 88    plateset.ce_switch = False
 89
 90    # Test resting permanent disable
 91    plateset.disengage_safety_protocols = True
 92    logger.write_info_to_report("Resting at 94°C")
 93    plateset.thermistor1 = 94
 94    plateset.disengage_safety_protocols = False
 95    serial_watcher.assert_false("flags.permanentdisable_overtemp", True)
 96
 97    serial_watcher.stop()
 98
 99
100def test_no_undertemp_faults():
101    """
102    | Requirement          | Confirm undertemp flags are disabled |
103    | :------------------- | :---------------------------------- |
104    | GitHub Issue         | #232 (BMS)                          |
105    | Instructions         | 1. Rest at -21°C and ensure no fault is raised </br>\
106                             2. Discharge at 100mA, -21°C and ensure no fault is raised </br>\
107                             3. Charge at 100mA, -5°C and ensure no fault is raised |
108    | Pass / Fail Criteria | Fail if a fault is raised |
109    """
110    logger.write_info_to_report("Testing Undertemp")
111    reset_cell_sims()
112    serial_watcher.start()
113
114    logger.write_info_to_report("Resting at -21°C")
115    plateset.thermistor1 = -21
116    serial_watcher.assert_false("flags.prefault_undertemp_discharge", True)
117    serial_watcher.assert_false("flags.fault_undertemp_discharge", True)
118
119    logger.write_info_to_report("Discharging at -100 mA, -21°C")
120    bms_hardware.load.mode_cc()
121    bms_hardware.load.amps = 0.100
122    bms_hardware.load.enable()
123    plateset.thermistor1 = -21
124    serial_watcher.assert_false("flags.prefault_undertemp_discharge", True)
125    serial_watcher.assert_false("flags.fault_undertemp_discharge", True)
126    bms_hardware.load.disable()
127
128    logger.write_info_to_report("Charging at 100 mA, -5°C")
129    bms_hardware.charger.set_profile(16.8, 0.100)
130    plateset.ce_switch = True
131    bms_hardware.charger.enable()
132    plateset.thermistor1 = -5
133    serial_watcher.assert_false("flags.prefault_undertemp_charge", True)
134    serial_watcher.assert_false("flags.fault_undertemp_charge", True)
135    bms_hardware.charger.disable()
136    plateset.ce_switch = False
137
138    serial_watcher.stop()
139
140
141def test_no_undervoltage_faults():
142    """
143    | Requirement          | Confirm undervoltage flags are disabled |
144    | :------------------- | :---------------------------------- |
145    | GitHub Issue         | #232 (BMS)                          |
146    | Instructions         | 1. Rest at 2.3V and ensure no fault is raised </br>\
147                             2. Charge at 500mA, 2.3V and ensure no fault is raised </br>\
148                             3. Charge at 500mA, 2.2V and ensure no permanentdisable is raised |
149    | Pass / Fail Criteria | Fail if a fault is raised |
150    """
151    logger.write_info_to_report("Testing Undervoltage")
152    reset_cell_sims()
153    test_cell = bms_hardware.cells[1]
154    for cell in bms_hardware.cells.values():
155        cell.disengage_safety_protocols = True
156        test_cell.exact_volts = 3.0  # Must be low enough to not trigger cell imbalance [abs(high - low) > 1.5V]
157    serial_watcher.start()
158
159    logger.write_info_to_report("Resting at 0 mA, 2.3 V")
160    test_cell.exact_volts = 2.3
161    serial_watcher.assert_false("flags.prefault_undervoltage_discharge", True)
162    serial_watcher.assert_false("flags.faultslumber_undervoltage_discharge", True)
163
164    bms_hardware.charger.set_profile(16.8, 0.500)
165    plateset.ce_switch = True
166    bms_hardware.charger.enable()
167
168    logger.write_info_to_report("Charging at 500 mA, 2.3 V")
169    serial_watcher.assert_false("flags.prefault_undervoltage_charge", True)
170    serial_watcher.assert_false("flags.fault_undervoltage_charge", True)
171
172    logger.write_info_to_report("Charging at 500 mA, 2.2 V")
173    test_cell.exact_volts = 2.2
174    serial_watcher.assert_false("flags.permanentdisable_undervoltage", True)
175
176    bms_hardware.charger.disable()
177    plateset.ce_switch = False
178
179    serial_watcher.stop()
180
181
182def test_no_cell_imbalance():
183    """
184    | Requirement          | Confirm cell imbalance flags are disabled |
185    | :------------------- | :---------------------------------- |
186    | GitHub Issue         | #232 (BMS)                          |
187    | Instructions         | Rest with one cell 1.5V+ below the others and ensure no fault is raised |
188    | Pass / Fail Criteria | Fail if a fault is raised |
189    """
190    logger.write_info_to_report("Testing Cell Imbalance")
191    reset_cell_sims()
192    test_cell = bms_hardware.cells[1]
193    serial_watcher.start()
194    test_cell.disengage_safety_protocols = True
195
196    logger.write_info_to_report("Resting at 0 mA, 2.0 V")
197    test_cell.exact_volts = 2.0
198    serial_watcher.assert_false("flags.prefault_cellimbalance", True)
199    serial_watcher.assert_false("flags.permanentdisable_cellimbalance", True)
200
201    serial_watcher.stop()