HILS - Hardware-in-the-Loop Simulation for ESS

300MW Battery Energy Storage System (BESS) Energy Management System

Real-time monitoring and control system for battery energy storage systems

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📋 Table of Contents

• Overview
• Screenshots
• Features
• Architecture
• System Requirements
• Installation
• Usage
• Project Structure
• User Interface
• Documentation
• Development
• Contributing
• License

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🎯 Overview

HILS (Hardware-in-the-Loop Simulation) EMS is a comprehensive Energy Management System designed for monitoring and controlling a 300MW Battery Energy Storage System (BESS). The system provides real-time control, monitoring, and analysis capabilities for large-scale energy storage installations.

Key Highlights

• Real-time Control: Direct control of battery charging/discharging and PCS (Power Conversion System) operations
• Comprehensive Monitoring: Live tracking of power, frequency, voltage, temperature, and battery SOC (State of Charge)
• Advanced UI: Modern 4-panel layout with intuitive controls and visual feedback
• Scalability: Supports multiple battery packs and PCS units
• Safety Features: Multi-level emergency stop system and comprehensive alarm management

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📸 Screenshots

Software Interface

Main Application Interface

HILS EMS v2.0 - Complete 4-panel layout showing battery control, center tabs, and real-time monitoring

Battery Pack SOC Control Panel

Left control panel - Battery SOC monitoring and charge/discharge control

EMS Control Interface

Complete control interface with battery and PCS management

Right Monitoring Panel

Real-time monitoring - Power, frequency, voltage, temperature, alarms, and events

HILS Battery Simulator

Real-time battery simulation interface with cycle testing

Battery Cycle BTS Client

Battery Testing System client interface for cycle management

Hardware & Laboratory Setup

HILS Cabinet and Rack Configuration

Complete HILS hardware cabinet with battery simulator and control systems

HILS Laboratory Overview

Laboratory setup showing equipment racks and thermal chamber

Power Monitoring Station

Dedicated power monitoring station for real-time data acquisition

Server Rack Console

Server rack with open console showing system configuration

Thermal Chamber Interior

Environmental thermal chamber for battery testing under controlled conditions

Thermal Monitor Device

Temperature monitoring device installed in cabinet

Battery & Power Systems

Battery Module Stack

Physical battery module stack for testing and validation

DC Power Supply Wiring

Rack-mounted DC power supplies with organized wiring

Environmental Monitoring System

LoRa Environment Sensor (Outdoor)

Rooftop environmental sensor with tripod mount and solar panel

Indoor Environment Sensor

Indoor environmental monitoring sensor with solar power

Environment Sensor PCB (RAK4630)

Close-up of RAK4630-based environmental sensor PCB

Sensor Head Assembly

Top view of environmental sensor head with components

Solar Node Components

Solar-powered sensor node components in natural light

LoRa Sensor on Workbench

LoRa environmental sensor development on workbench

Desk Solar Panel Prototype

Desktop solar panel prototype for sensor power testing

Data Acquisition & Analysis

DAQ Vibration Logger

Data acquisition system for vibration logging and analysis

Emissions Analyzer Station

Complete emissions analyzer station for environmental monitoring

Emissions Analyzer (Close-up)

Mobile emissions analyzer cart with measurement equipment

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✨ Features

🔋 Battery Management

• Real-time SOC monitoring and control
• Battery pack health status tracking
• Charge/discharge power control (-300MW to +300MW)
• Target SOC setting with slider controls
• Individual pack balancing and diagnostics

⚡ PCS Control

• Power Conversion System real-time control
• Multiple operation modes (Standby, Constant Power, Constant Frequency, Voltage Control, Auto)
• Frequency regulation (59.5-60.5Hz)
• Power output control with visual feedback
• System diagnostics and advanced configuration

📊 Monitoring & Visualization

• Real-time power trend charts
• SOC history visualization
• Frequency stability monitoring
• Grid interconnection status
• System efficiency tracking

🚨 Alarm & Event Management

• Real-time alarm monitoring with priority classification
• Event logging with timestamps
• Visual status indicators (color-coded)
• System health status dashboard

⚙️ System Configuration

• User permission management (Admin, Operator, Monitor)
• Communication protocol settings (Modbus TCP, DNP3, IEC 61850)
• System parameter configuration
• Email/SMS notification setup

🛡️ Safety Features

• Multi-level Emergency Stop System:
  • Individual PCS emergency stop
  • Overall system emergency stop
  • Individual battery pack isolation
• Real-time Diagnostics:
  • PCS diagnostic reports
  • Battery pack health checks
  • Overall system status summary
• Comprehensive Alarm System: Priority classification, email notifications

📈 Performance & Quality

• Efficient UI Updates: Redraw only changed components
• Memory Management: Timer and resource cleanup
• Scroll Optimization: Support for large data volumes
• Immediate Feedback: Confirmation messages for all control actions
• Error Handling: User-friendly error messages and recovery guides

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🏗️ Architecture

System Components

┌─────────────────────────────────────────────────────┐
│                   HILS EMS v2.0                     │
├──────────────┬──────────────────┬───────────────────┤
│  Left Panel  │   Center Panel   │   Right Panel     │
│              │                  │                   │
│  Battery     │   System Tabs    │   Monitoring      │
│  Control     │   - Overview     │   - Power         │
│              │   - Battery      │   - Frequency     │
│  PCS         │   - PCS Detail   │   - Voltage       │
│  Control     │   - Grid         │   - Temperature   │
│              │   - Charts       │   - Alarms        │
│              │   - Config       │   - Events        │
└──────────────┴──────────────────┴───────────────────┘

Core Class Structure

MainForm.java (Main UI Container)
├── Top Panel (Header) - java MainForm top
│   └── Time and system status display
├── West Panel (Left Control) - java MainForm west
│   ├── BatteryPackSOCPanel.java (Battery control)
│   └── PCSControlPanel.java (PCS control)
├── Center Panel (Tabs) - java MainForm center
│   ├── System Overview (PCSBMSSummery.java)
│   ├── BatteryStatusPanel.java
│   ├── PCSDetailStausPanel.java
│   ├── GridMonitorPanel.java
│   ├── RealTimeChartPanel.java
│   └── SystemConfigPanel.java
├── East Panel (Right Monitoring) - java MainForm east
│   ├── Real-time Data Panels (4 panels)
│   └── Alarm & Event Panels (2 panels)
└── Bottom Panel (Status Bar)
    └── System status and connection info

Technology Stack

• Language: Java 21
• Build Tool: Maven 3.9.x
• UI Framework: Java Swing
• Charting: JFreeChart 1.0.13
• Database: InfluxDB (embedded) 1.3.1
• Logging: Log4j 1.2.17 with SLF4J

Data Flow

1. Simulation-Based: Currently uses internal data model without actual equipment connection
2. Timer-Based Updates: Periodic updates using javax.swing.Timer
   • Header clock: 1 second
   • Battery data: 5 seconds
   • PCS data: 2 seconds
   • Right panel monitoring: 2 seconds
3. Event-Driven: Immediate response to user operations with confirmation dialogs

Independent Panel Execution

Each panel can be run independently for testing and development:

# Run specific panel only
java -cp target/classes org.hils.gui.MainForm top      # Header panel
java -cp target/classes org.hils.gui.MainForm west     # Left control
java -cp target/classes org.hils.gui.MainForm center   # Center tabs
java -cp target/classes org.hils.gui.MainForm east     # Right monitoring

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💻 System Requirements

Technology Stack

• Language: Java 21
• Build Tool: Maven
• GUI Framework: Java Swing
• Charts: JFreeChart 1.0.13
• Database: InfluxDB (embedded)
• Utilities: Lombok 1.18.26

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💻 System Requirements

Runtime Environment

• Java: JDK 21 or higher
• OS: Windows, macOS, or Linux
• Memory: 4GB RAM minimum (8GB recommended)
• Display: 1920x1080 or higher resolution

Development Environment

• Maven: 3.6+ for building
• IDE: IntelliJ IDEA, Eclipse, or VS Code with Java extensions

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🚀 Installation

1. Clone the Repository

git clone <repository-url>
cd HILS

2. Build the Project

mvn clean install

3. Run the Application

mvn exec:java -Dexec.mainClass="org.hils.App"

Or run directly from JAR:

java -jar target/HILS-0.0.1-SNAPSHOT.jar

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📖 Usage

Starting the Application

Full Application (Recommended)

# Using convenience script
./run-mainform.sh

# Or using Maven directly
mvn exec:java -Dexec.mainClass="org.hils.gui.MainForm"

# Or using Java directly
java -cp target/classes org.hils.gui.MainForm

Test Right Monitoring Panel

# Standalone right panel test with real-time simulation
./run-right-panel-test.sh

# Or using Java directly
java -cp target/test-classes:target/classes org.hils.gui.RightPanelTest

Individual Panel Testing

The application supports independent panel execution for development and testing:

# Test header panel only
java -cp target/classes org.hils.gui.MainForm top

# Test left control panel
java -cp target/classes org.hils.gui.MainForm west

# Test center tab panel
java -cp target/classes org.hils.gui.MainForm center

# Test right monitoring panel  
java -cp target/classes org.hils.gui.MainForm east

Test center panel only

java org.hils.gui.MainForm center

Test right monitoring panel only

java org.hils.gui.MainForm east

Test left control panel only

java org.hils.gui.MainForm west

Basic Operations

1. Battery Control

   • Adjust target SOC using the slider (20-100%)
   • Set charge/discharge power (-300 to +300 MW)
   • Click "Start Charge" or "Start Discharge"
   • Monitor real-time battery status

2. PCS Control

   • Select operation mode from dropdown
   • Adjust power output using slider
   • Set target frequency (59.5-60.5 Hz)
   • Click "Start Operation" to begin

3. Monitoring

   • View real-time data in right panel
   • Check alarm status
   • Review event logs
   • Monitor system efficiency

4. Emergency Stop

   • Click "Emergency Stop" button (red)
   • Available in both battery and PCS control panels
   • Immediately halts all operations

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📁 Project Structure

HILS/
├── src/
│   ├── main/
│   │   └── java/
│   │       └── org/
│   │           └── hils/
│   │               ├── App.java                    # Application entry point
│   │               ├── gui/
│   │               │   ├── MainForm.java          # Main UI container
│   │               │   ├── chart/
│   │               │   │   └── RealTimeChartPanel.java
│   │               │   ├── config/
│   │               │   │   └── SystemConfigPanel.java
│   │               │   ├── controls/
│   │               │   │   ├── BatteryPackSOCPanel.java
│   │               │   │   ├── PCSControlPanel.java
│   │               │   │   └── ...
│   │               │   ├── panels/
│   │               │   │   ├── BatteryStatusPanel.java
│   │               │   │   ├── GridMonitorPanel.java
│   │               │   │   ├── PCSDetailStausPanel.java
│   │               │   │   └── ...
│   │               │   └── ...
│   │               ├── property/
│   │               │   └── HProperty.java          # System properties
│   │               └── vo/
│   │                   ├── BMS.java
│   │                   ├── PCS.java
│   │                   └── ...
│   └── test/
│       └── java/
│           └── org/hils/gui/      # UI test classes
├── pom.xml                              # Maven configuration
├── README.md                            # This file
├── EMS_Screen_Configuration_Analysis_Consolidated.md
└── EMS_UI_Checklist.md

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🖥️ User Interface

4-Panel Layout

The HILS EMS v2.0 features a modern 4-panel layout:

1. Header Panel (Top)

• System title and identification
• Real-time clock display
• System status indicator

2. Left Control Panel (350px)

• Battery Control (Top 55%)

  • SOC display and control
  • Charge/discharge power settings
  • Control buttons (Charge, Discharge, Stop, E-Stop)

• PCS Control (Bottom 45%)

  • Power output control
  • Frequency regulation
  • Operation mode selection
  • Control buttons (Start, Stop, Reset, E-Stop, Diagnostics)

3. Center Tab Panel (Main Content)

• System Overview: PCS/BMS summary
• Battery Status: Detailed battery monitoring
• PCS Detail: PCS system control
• Grid Monitor: Grid interconnection status
• Real-time Charts: Power, SOC, frequency trends
• System Config: Settings and configuration

4. Right Monitoring Panel (350px)

• Real-time data panels (Power, Frequency, Voltage, Temperature)
• Alarm status panel
• Event log panel

5. Status Bar (Bottom)

• Connection status
• Data status
• System version
• Overall system state

Color Coding

• 🟢 Green: Normal operation (SOC > 80%)
• 🟠 Orange: Caution (SOC 50-80%)
• 🔴 Red: Warning (SOC < 20%) or fault condition
• ⚫ Gray: Inactive or stopped

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📚 Documentation

Comprehensive documentation is available in the docs folder:

• EMS Screen Configuration Analysis

  • Detailed UI component analysis
  • Screen structure and layout
  • Data structures and class mappings
  • Technical implementation details

• UI Checklist

  • Completed features checklist
  • Pending improvements
  • Development roadmap

• GUI Issues and Corrections

  • Identified GUI implementation issues
  • Correction requirements
  • Implementation checklist

• GUI Corrections Applied Summary

  • Summary of applied corrections
  • Label conversions (Korean to English)
  • Panel identification comments

• Right Panel Improvements

  • Detailed right panel enhancements
  • Font size improvements (16pt → 20pt)
  • Real-time simulation features

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🛠️ Development

Building from Source

# Clean and compile
mvn clean compile

# Run tests
mvn test

# Package JAR
mvn package

# Install to local repository
mvn install

Running Tests

# Run all tests
mvn test

# Run specific test
mvn test -Dtest=ImageLoadTest

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🖥️ Screen Configuration (v2.0)

Main Frame Layout

The EMS v2.0 implements a modern 4-panel layout optimized for real-time control and monitoring:

┌─────────────────────────────────────────────────────────────────────────┐
│                         Header Panel                                    │
│  🔋 EMS | 300MW BESS | 🟢 System Normal | 2024.10.29 15:30               │
│          Real-time Monitoring & Control System                          │
├──────────────┬───────────────────────────────────┬──────────────────────┤
│ Left Control │      Center Tab Panel             │ Right Monitoring     │
│  (350px)     │                                   │     (350px)          │
│              │                                   │                      │
│⚡ Battery     │ [System][Battery][PCS][Grid]      │ Power: 150.5MW       │
│  & PCS       │ [Charts][Config]                  │ Freq: 60.05Hz        │
│  Control     │                                   │ Voltage: 22.9kV      │
│              │   Current Tab Content             │ Temp: 25.3°C         │
│ Battery:     │                                   │                      │
│ - SOC Target │                                   │ Alarm Status         │
│ - Power Set  │                                   │ Event Log            │
│ - Charge     │                                   │                      │
│ - Discharge  │                                   │                      │
│ - Stop       │                                   │                      │
│ - E-STOP     │                                   │                      │
│              │                                   │                      │
│ PCS:         │                                   │                      │
│ - Set Power  │                                   │                      │
│ - Frequency  │                                   │                      │
│ - Mode       │                                   │                      │
│ - Start/Stop │                                   │                      │
│ - Diag       │                                   │                      │
├──────────────┴───────────────────────────────────┴──────────────────────┤
│                         Status Bar                                      │
│ 🔌 Connected | 📊 Data Normal | ⚠️ No Alarms    EMS v2.0 | Ready         │
└─────────────────────────────────────────────────────────────────────────┘

Panel Details

Header Panel

• Purpose: System identification, status, and time information
• Components:
  • Left: 🔋 EMS icon and system name
  • Center: "300MW BESS Energy Management System" title
  • Right: 🟢 System status + real-time clock (yyyy.MM.dd HH:mm:ss)
• Update Cycle: Clock updates every 1 second, status every 5 seconds

Left Control Panel (350px width)

Purpose: Real-time direct battery and PCS control

Battery Control Panel (Top 55%):

• Total SOC display (85.2%)
• Average voltage display (3.85V)
• Temperature monitoring (25.3°C)
• Target SOC slider (20-100%)
• Charge/discharge power setting (±300MW)
• Control buttons: Charge, Discharge, Stop, Emergency Stop

PCS Control Panel (Bottom 45%):

• Output power display (150.5MW)
• Frequency display (60.0Hz)
• Voltage/efficiency monitoring
• Set power slider (±300MW)
• Target frequency spinner (59.5-60.5Hz)
• Operation mode selection (Standby, Power Control, Frequency Control, etc.)
• Control buttons: Start, Stop, Reset, E-STOP, Diagnostics, Config

Center Tab Panel

6 tabs for detailed system management:

1. System Overview: PCS/BMS summary + additional controls
2. Battery Status: Detailed battery system monitoring
3. PCS Detail Control: PCS detailed control and monitoring
4. Grid Monitor: Power grid interconnection monitoring
5. Real-time Charts: Power, SOC, frequency visualization
6. System Config: System parameters and settings management

Right Monitoring Panel (350px width)

Real-time data monitoring (No controls):

Top Section (4 panels):

• ⚡ Power Monitoring: 150.5MW, Charging status
• 📊 Frequency Monitoring: 60.05Hz, Normal status
• 🔌 Voltage Monitoring: 22.9kV, Normal status
• 🌡️ Temperature Monitoring: 25.3°C, Normal status

Bottom Section (2 panels):

• ⚠️ Real-time Alarms: Active alarm status
• 📋 System Events: Event log with timestamps

Status Bar

• Left: 🔌 Connection, 📊 Data, ⚠️ Alarm status
• Right: EMS v2.0 version, System ready status

Data Structures

Battery-Related

• BatteryStatus: SOC, SOH, voltage, current, temperature, cell min/max voltage
• BatteryPackInfo: Pack ID, capacity, health status

PCS-Related

• PCSControlData: PCS ID, online status, operation mode, power, voltage, current, frequency
• PCSSummery: PCS summary data
• PCSStatus: Detailed PCS status

System Configuration

• HProperty: Screen size, supply power (300MW)
• SystemConfigPanel: Protocols (Modbus TCP, DNP3, IEC 61850), user management, alarms

Class Mapping

Screen Component	Class File	Location
Main Frame	MainForm.java	org.hils.gui
Battery Control	BatteryPackSOCPanel.java	org.hils.gui.controls
PCS Control	PCSControlPanel.java	org.hils.gui.controls
Battery Status Tab	BatteryStatusPanel.java	org.hils.gui.panels
PCS Detail Tab	PCSDetailStausPanel.java	org.hils.gui.panels
Grid Monitor Tab	GridMonitorPanel.java	org.hils.gui.panels
Real-time Charts	RealTimeChartPanel.java	org.hils.gui.chart
System Config	SystemConfigPanel.java	org.hils.gui.config
Right Monitoring	MainForm.java	Integrated in main form

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📄 License

Custom License - Free for Personal Use, Commercial License Required

This software is free to use for personal, educational, and non-commercial purposes. Commercial use requires a separate license agreement.

• ✅ Free: Personal use, education, research
• ❌ Requires License: Commercial use, production deployment, integration into commercial products

For commercial licensing inquiries, please contact: hyun.lim@okkorea.net

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📞 Contact & Services

Development Consulting & Outsourcing Available

We provide professional consulting and development services for IoT, AI, and embedded systems projects.

👨‍💼 Project Manager Contact

• Email: hyun.lim@okkorea.net
• Homepage: https://www.okkorea.net
• LinkedIn: https://www.linkedin.com/in/aionlabs/

🛠️ Technical Expertise / 기술 전문 분야

• IoT System Design and Development / IoT 시스템 설계 및 개발
• Embedded Software Development / 임베디드 소프트웨어 개발 (Arduino, ESP32)
• AI Service Development / AI 서비스 개발 (LLM, MCP Agent)
• Cloud Service Architecture / 클라우드 서비스 구축 (Google Cloud Platform)
• Hardware Prototyping / 하드웨어 프로토타이핑

💼 Services / 서비스

• Technical Consulting / 기술 컨설팅

  • IoT project planning and design consultation / IoT 프로젝트 기획 및 설계 자문
  • System architecture design / 시스템 아키텍처 설계

• Development Outsourcing / 개발 외주

  • Full-stack development from firmware to cloud / 펌웨어부터 클라우드까지 Full-stack 개발
  • Proof of Concept (PoC) development / 개념 검증 개발
  • Production-ready system development / 상용 시스템 개발

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Built with ❤️ for Energy Storage Management

Documentation • Checklist