3.1.

4 Battery Management System

Battery Management System or BMS may be as simple as electronics to measure voltage and stop charging
when the desired voltage is reached. At that point, they might shut down the power flow; in the event of irregular or
dangerous conditions, they might issue an alarm. In our system, it should also perform more complex functions like
monitoring many factors that affect battery life and performance as well as ensuring safe operation. It should monitor
multi-cell battery systems. Multi-cell systems may monitor and control conditions of individual cells.

Figure 00: Battery management system

Design process of BMS

The various steps involved in design process of BMS are as follows: -

Step 1: Conceptualization

In order monitor and optimize battery performance and safety it is necessary to understand what needs to be
controlled and why it needs controlling. This requires an in-depth understanding of the fundamental cell chemistries,
various battery failure modes etc. Some of the factors which needs to be decided for the start of BMS design are:

 Battery Pack configuration

 Cost constraints
 Volume constraints
 Features to be included in design
 Figure 00: Various components in BMS

Step 2: Selection of type of BMS

There are two types of BMS based on its type, they are Analog and Digital BMS. So, in this step, we will be
selecting type of BMS to be used depending upon our requirements like

 Cell protection
 Charge control
 Demand management
 State of charge determination
 Cell balancing
 History (Log book function)
 Authentication and Identification
 Communication

Step 3: Topology Selection

Depending on our requirements we will be selecting type of Topology used in BMS which will decide type
of hardware configuration for a BMS. These are the following types of topologies from which we can select \

 Centralized
 Modular
 Distributed

Step 4: Hardware Design

In this step various hardware system will be designed for the BMS based upon selected topology. Various
systems which will come under this are:

4.1 Design of Battery monitoring unit

Based on Topology, a processor will be selected for the system. Processor together with other subsystems
will collectively form Battery monitoring system. These sub-systems are Battery SOC and SOH module, Comparator
logic, Log book chip etc.

4.2 Design of system Interface

After selecting different components and subsystems of the BMS we need to interface all the components
together. Below systems needed to be interfaced with each other in a BMS:

 Sensors
 Safety systems
 Comparators
 Log book chip
 Thermal Management unit
 Battery monitoring unit

4.3 Design of Safety systems

We need to design safety systems for our BMS as its the key feature for any BMS in case of failure of any
subsystem or any unforeseen conditions in the Battery pack. Different types of safety systems are designed in this
stage for cell protection for the following undesirable events or conditions:

 Excessive current during charging and discharging

 Short circuit
 Over-voltage and Over-charging
 Under voltage - Exceeding present depth of discharge (DOD) limits
 Over-heating
 System isolation in case of accident
 Pressure built up inside a cell

Step 5: Design of Data Acquisition System

Data acquisition is important as we need to send all the parameters from one place to another place so there
may be losses and noises so in this stage different types of sensors system are designed to measure real-world
parameters and sent to the processor after multiple stages as follows:

5.1 Sensor selection

Different types of sensors are selected to acquire data from battery cells such as

 Voltage
 Temperature
  Current
 Pressure

5.2 Sensor calibration tests

After selecting our sensors, we need to make appropriate circuits for them and then it needs to be calibrated
in order to achieve the best possible accuracy, a sensor should be calibrated in the system where it will be used.
Each sensor will have a ‘characteristic curve’ that defines the sensor’s response to an input. The calibration process is
done using different calibration methods and results are mapped according to the sensor’s response to an ideal linear
response. How to best accomplish that depends on the nature of the characteristic curves such as:

 Offset
 Sensitivity or Slope
 Linearity

5.3 Design of Signal Conditioning

In this step, transducers are connected to sensors for converting physical parameters into an electrical
waveform for Signal processing where signal conditioning circuits are designed to improve the quality of signal
generated by transducers before they are converted into digital signals.

5.4 Design of Data Processing Unit

In this stage, we design a data processing unit where the obtained data needed to send to the processor
using A/D converters as a processor only read digital values. A software with compatibility is programmed and
designed which will be controlled by the processor for Data acquisition depending upon our requirements.

Step 6: Design of charge control system

Depending upon our application and battery pack a specific type of charge control system is designed for
charging cells. Different Charge control methods are used depending on different types of sources and chargers.
Following parameters and methods are taken into consideration while selection:

 Charging schemes
 Charging time
 Hysteresis
 Charging efficiency

Step 7: Design of Communication channel

A bus is designed to provide secure communications in the very harsh operating environments with high
levels of electrical noise which are found in automotive systems where it should define the following communication
protocols

 Method of addressing the device connected to bus

 Data word format
 Priority setting
 Transmission sequence
 Control signals
 Error detection
 Error handling or correction
  Transmission speed

Step 8: Design of Cooling System

As the cells are balanced by discharging through the load cells inside the BMS and other ohmic losses of
components like processor will generate the heat which is needed to be eliminated from the BMS. Cooling system is
designed based on the following factors

 Amount of heat generated

 Airflow available
 Mounting position in the bike

Step 9: Software Design

Based on the selected hardware and system various software algorithms will be designed. In those algorithms,
various sequence and parameters will be decided based upon BMS will detect and respond. In this User’s interface
will also be designed by which user will interact with the system. An LCD/LED screen is used to display all the useful
information to the user. Some of the algorithms designed in this step are:

 State of Health of cell (SOH)

 State of charge (SOC)
 Cell balancing algorithm design
 Figure 00: BMS working algorithm flow chart

Step 10: Software and hardware integration

In this step software and hardware will be integrated together.

10.1 Software in loop

SIL is used to test all the different algorithms with a modeling software. All the fault systems are tested and
most software errors are rectified at this stage.

10.2 Processer in loop

After the software is developed we need to check it in our processor, so instead of reading the physical
sensors, values calculated by the simulation tool are used as inputs to the embedded algorithm. Similarly, outputs of
the control algorithms executing on the processor are fed back into the simulation to drive the virtual environment.
10.3 Hardware in loop

In an HIL simulation, it includes electrical emulation of sensors. These electrical emulations act as the
interface between the plant simulation and the BMS under test. The value of each electrically emulated sensor is
controlled by the plant simulation and a checklist is made for hardware systems. Most of the hardware errors can be
found at this stage.

Step 11 Assembly and Testing

Once the BMS has passed through the respective quality checks the assembly process begins, taking great
care in protecting all the components. The technician assembles all the components and ensures that every component
is in its place, aligned and adjusted in line with specifications. To ensure that every component is assembled faultlessly,
thorough checks are carried out to test the integrity of these components, in some instances, it may require new wiring,
relays, fuses, etc. if there is any error. As part of the Assembly process, the BMS needs to be reconnected to check the
software and hardware integration. After assembly of the BMS has been completed a comprehensive test is carried
out and corrections will be carried out if necessary.

Prototype Testing is conducted with the intent of finding defects before the BMS goes live. Prototype Testing
allows seamlessly to collect quantitative, qualitative, and behavioral data while evaluating BMS.