OUSD (R&E) CRITICAL TECHNOLOGY AREA(S): Integrated Sensing and Cyber The technology within this topic is restricted under the International Traffic in Arms Regulation (ITAR), 22 CFR Parts 120-130, which controls the export and import of defense-related material and services, including export of sensitive technical data, or the Export Administration Regulation (EAR), 15 CFR Parts 730-774, which controls dual use items. Offerors must disclose any proposed use of foreign nationals (FNs), their country(ies) of origin, the type of visa or work permit possessed, and the statement of work (SOW) tasks intended for accomplishment by the FN(s) in accordance with the Announcement. Offerors are advised foreign nationals proposed to perform on this topic may be restricted due to the technical data under US Export Control Laws. OBJECTIVE: Battery Management System (BMS) cybersecurity verification technologies and equipment for ensuring Li-ion battery pack BMS cybersecurity during manufacture. DESCRIPTION: Lithium-ion battery technologies, both low-voltage and high-voltage, are a critical technology to enhance energy storage to improve warfighting performance across the Army, Marines, and Navy as they provide increased silent watch time, significantly extended cycle life, and faster recharge time. These batteries are integrating into existing platforms (Stryker, Abrams, JLTV, HMMWV), the Next Generation Combat Vehicle (NGCV) Program, and other Weapon Systems. Lithium-ion battery packs for Defense Logistics Agency procurement, such as the Lithium-ion 6T (MIL-PRF-32565C) or aviation batteries (MIL-PRF-29595B), require a Battery Management System (BMS), which is a complex embedded hardware and software system that controls the charge & discharge of the pack to ensure safety and performance requirements are met. The BMS coordinates a number of inputs, such as cell voltages, pack voltage, current, and temperatures, and controls a number of outputs including the battery heaters and contactors. BMS safety protections include Overcharge, Over-discharge, Overcurrent, Short circuit, Over-temperature, and Low temperature charge protection. Existing literature on cybersecurity for conventional commercially used BMS defines a number of possible methods of compromise, including hardware & software Trojans, i.e. malicious circuit & firmware modifications, and defines a number of possible resulting outcomes including loss of vehicle power, degraded performance/life of the battery (negatively affecting cost of ownership), and safety system violations resulting in battery abuse conditions or unexpected battery shutdowns (contactors opening). Therefore, there is a need to develop innovative technologies which allow for the verification of Li-ion battery pack BMS cybersecurity at the time of manufacture, including Cyber-physical aspects, in order to prevent damage as well as to protect and restore systems, to ensure its availability, integrity, and authenticity. Technologies developed shall consider distributed BMS architecture where there is a master-level controller and multiple module-level controllers. Technology developed shall also ensure that batteries remain in and transition to and from the proper battery states under the proper conditions, such as Dormant, Initialize, Operational, Standby, Maintenance, Protected, and Battle override. Technology developed should be generally applicable to all Lithium-ion BMSs, including low-voltage and high-voltage BMS. Additionally, technologies developed shall also consider equalization as well as dependency on the battery's current state, including its State of Charge (SOC) and State of Health (SOH). The BMS includes advanced algorithms to accurately compute SOC, SOH, Time Remaining, and Power Capability. Given the complex & often proprietary nature of these advanced algorithms, being able to assess reported values over a wide range of simulated conditions applied to the BMS is desired to allow for verifying the integrity of the data provided as this information is used in system-level controls. Therefore, there is a need for a fast, repeatable, & precise means of assessing the accuracy & integrity of BMS SOC & SOH algorithms through Hardware-in-the-Loop (HIL) Simulation, over the entire battery cycle life and against specific vehicle platform operational profiles. Moreover, after BMS firmware & hardware changes, algorithms must be reassessed to ensure necessary accuracy & data integrity are still met. The proposed solution shall include a BMS Cybersecurity Verification System capable of testing the BMS in a manufacturing line prior to insertion into a battery pack using HIL simulation with embedded system hardware & software verification. PHASE I: Direct To Phase II must provide a proof of concept. The successful proposal must provide product specification/marketing sheets and information documenting the vendor's solution is based on existing Battery Management System (BMS). As well as Manufacturing Validation/Test Equipment and multi-channel BMS Hardware-in-the-Loop (HIL) Validation/Testing Equipment. Preferably with documented use in a manufacturing environment. This type of equipment is the necessary basis for this BMS cybersecurity testing capability, including cyber physical aspects. PHASE II: Not to exceed a duration of 24 months and cost of $1,000,000 Develop and integrate prototype hardware and software solutions into manufacturing equipment using existing designs and technologies. The BMS Cybersecurity Verification System shall be capable of integration into a high-volume 6T production process of at least 500 packs/month. The BMS Cybersecurity Verification System shall address both hardware- and software-based methods of compromise and will verify performance characteristics, range, resolution, and error of BMS measured parameters. The Verification System shall also be capable of being updated to address emerging methods of compromise. Cybersecurity solutions shall also consider the Cybersecurity Test and Evaluation Process (see references), Defense-in-Depth information assurance, as well as FIPS authentication, digital signature, & standards and include the ability to detect malware and test code validity. Deliverables shall include electrical drawings and technical specifications; software; interface documents; M&S and test results; one BMS Cybersecurity Verification System prototype capable of meeting the high-volume manufacturing requirements; and one scaled-down version of the BMS Cybersecurity Verification System capable of testing up to one BMS at a time in a laboratory test environment. The BMS Cybersecurity Verification System shall be designed to interface with at least one BMS design from a Li-ion 6T pack product. Integration of the technology developed and demonstration on an existing Li-ion 6T manufacturing process and production line capable of at least 200 packs/month is expected in this phase. Testing of the BMS Cybersecurity Verification System design shall include mock manufacturing runs using small production batches of Li-ion 6T BMSs prior to installation into Li-ion 6T batteries. The BMS Cybersecurity Verification System shall be capable of integration into a high-volume Li-ion 6T manufacturing process and production line. A bill of materials and volume part costs for the Phase II designs should also be developed. This phase also needs to address the challenges identified in the above description and meet the requirements of Phase I for the underlying technology. PHASE III DUAL USE APPLICATIONS: This phase will begin installation and integration of the solutions developed in Phase II into military Li-ion 6T and commercial Li-ion pack production processes and into low- to high-volume manufacturing lines as well as into Li-ion 6T and commercial Li-ion battery chargers and BMS. The scalability of the technology to high-volume production of up to 2000 packs/month should also be demonstrated based upon throughput and rate capabilities of the BMS Cybersecurity Verification System. Compatibility and integration with other military Lithium-ion format batteries is expected. REFERENCES: 1. CHEAH, Madeline, and Richard STOCKER. "Cybersecurity of Battery Management Systems." 2. Kumbhar, Sourabh, et al. "Cybersecurity for battery management systems in cyber-physical environments." 2018 IEEE Transportation Electrification Conference and Expo (ITEC). IEEE, 2018. 3. Khalid, Asadullah, et al. "Facts approach to address cybersecurity issues in electric vehicle battery systems." 2019 IEEE Technology & Engineering Management Conference (TEMSCON). IEEE, 2019. 4. Kim, Taesic, et al. "An overview of cyber-physical security of battery management systems and adoption of blockchain technology." IEEE Journal of Emerging and Selected Topics in Power Electronics (2020). 5. Rahman, Syed, et al. "A Study of EV BMS Cyber Security Based on Neural Network SOC Prediction." 2018 IEEE/PES Transmission and Distribution Conference and Exposition (T&D). IEEE, 2018. 6. Dey, Satadru, and Munmun Khanra. "Cybersecurity of Plug-in Electric Vehicles: Cyber Attack Detection During Charging." IEEE Transactions on Industrial Electronics (2020). 7. Sripad, Shashank, et al. "Vulnerabilities of electric vehicle battery packs to cyberattacks." arXiv preprint arXiv:1711.04822 (2017). 8. Ebner, Arno, Fiorentino Valerio Conte, and Franz Pirker. "Rapid validation of battery management system with a dymola hardware-in-the-loop simulation energy storage test bench." World Electric Vehicle Journal 1.1 (2007): 205-207. 9. Zhang, Yongzhi, et al. "Lithium-ion battery pack state of charge and state of energy estimation algorithms using a hardware-in-the-loop validation." IEEE Transactions on Power Electronics 32.6 (2016): 4421-4431. 10. Barreras, Jorge Varela, et al. "An advanced HIL simulation battery model for battery management system testing." IEEE Transactions on Industry Applications 52.6 (2016): 5086-5099. 11. Dai, Haifeng, et al. "Cell-BMS validation with a hardware-in-the-loop simulation of lithium-ion battery cells for electric vehicles." International Journal of Electrical Power & Energy Systems 52 (2013): 174-184. 12. Cybersecurity Test and Evaluation Process , www.dau.edu, June 2018. 13. Federal Information Processing Standards (FIPS) , https://www.nist.gov. 14. Performance Specification: Battery, Rechargeable, Sealed, 6T Lithium-ion , MIL-PRF-32565C, https://assist.dla.mil. 15. Performance Specification: Batteries, Lithium, Rechargeable, Aircraft MIL-PRF-29595B, https://assist.dla.mil. KEYWORDS: Cybersecurity, manufacturing, Battery Management Systems, BMS, Lithium-ion, 6T, batteries, electric vehicle, firmware
