Enhancement of Active Battery Management System

with Fast Charging Technology

A PROJECT REPORT

Submitted by

SASIDHARAN S. (711317105087)

KUMARAN G. (711317105059)

MARIESH M. (711317105067)

in partial fulfillment for the award of the degree

of

BACHELOR OF ENGINEERING

in

ELECTRICAL AND ELECTRONICS ENGINEERING

KPR INSTITUTE OF ENGINEERING AND TECHNOLOGY

` ARASUR

COIMBATORE

OCTOBER 2019
 BONAFIDE CERTIFICATE

Certified that this project report “ Enhancement of Active Battery Management

System with Fast Charging Technology ” is the bonafide work of
“SASIDHARAN.S, KUMARAN.G, MARIESH.M” who carried out the project
work under my supervision.

SIGNATURE SIGNATURE

Dr.V.KUMAR CHINNAIYAN Ms.R.REVATHI

HEAD OF THE DEPARMENT, SUPERVISOR,

Professor, Assistant Professor,

Department of Electrical and Department of Electrical and

Electronics Engineering, Electronics Engineering,

KPR Institute of Engineering KPR Institute of Engineering

and Technology, Arasur. and Technology, Arasur.
 TABLE OF CONTENTS
CHAPTER NO TITLE PAGE NO

ABSTRACT

LIST OF TABLES

LIST OF FIGURES

LIST OF ABBREVIATIONS

1 INTRODUCTION 5

1.1 BLOCK DIAGRAM

1.2 WORKING PRINCIPLE
2 HARDWARE DESCRIPTION 8

2.1 LITHIUM ION BATTERIES

2.2 ACTIVE BMS

2.3 RELAY MODULE

2.4 POWER SUPPLY

2.5 BATTERY HOLDER

2.6 NICKEL STRIP

3 MERITS AND DEMERITS

3.1 APPLICATIONS 13

4 CONCLUSION AND

FUTURE ENHANCEMENT

REFERENCE 15
 ABSTRACT

Electric vehicle drives offer a number of advantages over

conventional internal combustion engines, especially in terms of lower local

emissions, higher energy efficiency, and decreased dependency upon oil.

Lithium-ion battery power systems have been commonly used for energy storage

in electric vehicles. In existing vehicle the charging time nearly takes around 4

to 6 hours. This project presents the innovative solution for the battery charging

technology and also ensures protection in a battery-power system .The active

BMS (Battery Management System) is incorporated with our battery as a result

the life cycle of the battery gets increased. This extends the lifetime of battery

and provides an added layer of protection by preventing damage to a battery cell

due to deep discharging and overcharging. It increase system run time by

increasing the total useable charge in the battery stack, decreasing charge time

compared with passive balancing, and decreasing heat generated while

balancing. By using this technology, the entire battery backup can be charged

within 15 minutes.
 CHAPTER 1

1. INTRODUCTION

As one of many energy storage solutions, lithium-ion batteries (LIBs) are

attracting more and more attention from researchers and users due to their high
energy density, high power density, long lifespan and environmental friendliness
. There are broad applications in high-power applications such as electric vehicles
using large numbers of serial or parallel battery cells. The safety of the LIB
power system is crucial, especially when the battery-power system is grouped by
a considerable number of battery cells in serial or parallel topology, or in a battery
stack, to give a higher power density. The LIBs can deteriorate if they are to
operate beyond the battery specifications.
The estimations of SOC in the battery management system (BMS) can improve
the system performance and reliability. There are several kinds of LIBs in the
market, such as those containing LiFeO4, lithium polymers and LiCoO2. With the
different dynamic behavior of the batteries and their topology, specific SOC
algorithms are sometimes required. There have been many development and
research works in recent years to improve SOC estimation accuracy. Ampere-
hour (Ah) methods, as well as the open-circuit voltage (OCV) and impedance
measurement methods, give a more intuitive and reliable estimation. , the smart
battery-power system has the following features: (1) compatibility and flexibility
with different kinds of LIBs and battery pack configurations; (2) capability for
SOC self-initialization and self-adjustment. It is followed by Section that deals
with the implementation and demonstration of the proposed system in a 15S
battery-pack prototype
 1.1 BLOCK DIAGRAM AND ITS DESCRIPTON:

A B C D E F

B C
D E (NO)

A C E (+)

B D F (-) (NC)

Figure 1.1: Relay connection

The primary goal of a BMS is to keep the battery from operating out of its safety
zone. The BMS must protect the cell from any eventuality during
discharging. Batteries are more frequently damaged by inappropriate charging than
by any other cause. Therefore, charging control is an essential feature of the BMS.
Both active and passive cell balancing are effective ways to improve system health
by monitoring and matching the SOC of each cell. Active cell balancing
redistributes charge during the charging and discharging cycle, unlike passive cell
balancing, which simply dissipates charge during the charge cycle. Thus active cell
balancing increases system run-time and can increase the charging efficiency.

1.2 WORKING PRINCIPLE:

Here we have used both serial and parallel combination batteries. While they
are connected in series the output power is used for discharging. Meanwhile when
they are connected in parallel it is used for charging. The series connection for
discharging and parallel connection for charging is switched by using contactor.
The contactor consists of two mode of connection, normally closed (NC) and
normally open (NO). In Normally Open condition the batteries are connected in
parallel and it is used for charging the battery. In Normally Closed condition the
batteries are connected in series and it is used for discharging purpose. An input
supply is provided from the battery to the contactor for switching between
Normally Open and Normally Closed condition

CIRCUIT DIAGRAM:
 Figure 1.2: Battery Management System

CHAPTER 2
2. HARDWARE DESCRIPTION:
2.1 LITHIUM ION BATTERIES:
A lithium ion phosphate (LiFePO4) battery is a type of lithium-ion battery
that is capable of charging and discharging at high speeds compared to other types
of batteries.
 TABLE 2.1
S.No
Item Condition/ Notes Specification Remarks
2.1 Nominal Capacity 1 C discharge capacity ≥6 Ah

2.2 AC Impedance At AC 1000 Hz ≤8 mΩ

2.3 Nominal Voltage 3.2 V

32.2±0. 3 mm Excluding plastic
Cell Diameter parts
Max. 32.5 mm
2.4 Cell Size 70.5±0. 3 mm outside.
Cell Height
Max. 70.8 mm
Excluding plastic
2.5 Cell Weight (Bare cell) 140±5 g parts
outside.
2.6 End-of-charge Voltage CC Mode 3.65 V

2.7 End-of-charge Current CV Mode 0.275 A

Standard Charging 1 C at CC/CV 60 min

2.8 Charging Method
Max Continuous 6 C at CC/CV 10~15 min
Charging
2.9 End-of-discharge Voltage CC Mode 2.0 V
2.10 Max continuous Discharging
33 A
Current
2.11 Max Pulse Discharging Current 55 A 5s

2.13 Life Cycle 1 C/ 70 % DOD ≥3000 cycles

Operating Charging 0~65 °C

2.14 Temperature
Temperat
Discharging
ure -20~ 65°C
Temperature
Range
Storage 1 year 10~ 45°C
Temperature
2.15 Appearance Without break, scratch, distortion, contamination, leakage and
so on
2.2 ACTIVE BMS:
A Battery Management System (BMS) is any electronic system that
manages a rechargeable battery (cell or battery pack), such as by protecting
the battery from operating outside its safe operating area, monitoring its state,
calculating secondary data, reporting that data, controlling its environment.
They manage the output, charging and discharging and provide notifications on the
status of the battery pack. They also provide critical safeguards to protect
the batteries from damage. A BMS may protect its battery by preventing it from
operating outside its safe operating area

 Over-current (may be different in charging and discharging modes)

 Over-voltage (during charging)
 Under-voltage (during discharging), especially important for Li-ion cells
 Over-temperature
 Under-temperature
 Over-pressure (LiFePO4 batteries)
 Ground fault or leakage current detection (system monitoring that the high
voltage battery is electrically disconnected from any conductive object
touchable to use like vehicle body)

The BMS may prevent operation outside the battery's safe operating area by:

 Including an internal switch (such as a relay or solid state device) which is

opened if the battery is operated outside its safe operating area
 Requesting the devices to which the battery is connected to reduce or even
terminate using the battery.
  Actively controlling the environment, such as through heaters, fans, air
conditioning or liquid cooling
 A BMS may also feature a recharge system allowing a safe way to connect
the battery to different loads and eliminating the excessive inrush currents to
load capacitors.

2.3 RELAY MODULE:

It works on the principle of an electromagnetic attraction. When the circuit

of the relay energizes the electromagnetic field which produces the temporary
magnetic field. This magnetic field moves the relay armature for opening or
closing the connections. It has an iron core which is wound by a control coil. The
power supply is given to the coil through the contacts of the load and the control
switch. The current flows through the coil produce the magnetic field around it.
Due to this magnetic field, the upper arm of the magnet attracts the lower arm.
Hence close the circuit, which makes the current flow through the load. If the
contact is already closed, then it moves oppositely and hence opens the contacts.
The relay consist of two modes of operation, Normally Open (NO) and Normally
Closed (NC). It can be switched between these two modes by energizing the relay.

2.4 POWER SUPPLY:

A power supply is an electrical device that supplies electric power to an electrical

load. The primary function of a power supply is to convert electric current from a
source to the correct voltage, current, and frequency to power the load. As a result,
power supplies are sometimes referred to as electric power converters. Power
supplies often have protection from short circuit or overload that could damage the
supply or cause a fire. Fuses and circuit breakers are two commonly used
mechanisms for overload protection.

2.5 BATTERY HOLDER:

A battery holder is one or more compartments or chambers for holding
the battery. For dry cells, the holder must also make electrical contact with the
battery terminals. For wet cells, cables are often connected to the battery terminals,
as is found in automobiles or emergency lighting equipment. A battery holder is
either a plastic case with the shape of the housing moulded as a compartment that
accepts a battery or batteries, or a separate plastic holder that is mounted with
screws.

2.6 NICKEL STRIP:

Nowadays, Li-ion battery cells have been used in many applications such as
pure electric/hybrid vehicles, electronic mobile devices because of high energy
density. However, single battery cell cannot be used in a battery pack because its
voltage and current density are not enough for operation. Therefore, many battery
cells must be assembled and connected in serial/parallel for battery packs.
Consequently, many electrical connectors are required as electrical bridges
between battery cells. For most 32650 Li-ion battery cells, spot technique can be
used to weld a sheet metal connector with a battery cell. In general, the spot
welding technique is widely used more than the laser welding technique because
its infrastructure cost is lower. The welding parameters include electrode tip
 geometry, connecting strip material and design, maximum supply voltage, welding
time welding force and distance between two electrodes.
 PURE NICKEL: The USS-PNS00006 has a Nickel content of 99.6% giving it a
pure nickel rating. Pure nickel will never corrode and come loose in high drain
application.
 SOLDERING AND WELDING: Pure Nickel Strips are mainly used in the
battery welding and soldering field due to their excellent oxidation resistance,
corrosion resistance, low resistance and high conductivity attributes, and pure
nickel can also easily be soldered and welded.
CHAPTER 3
3. MERITS AND DEMERITS:
MERITS:
 Active cell balancing redistributes charge during the charging and
discharging cycle, unlike passive cell balancing, which simply dissipates
charge during the charge cycle.
 Thus active cell balancing increases system run-time and can increase the
charging efficiency.
 Lithium is quick and efficient.
 Fast charging minimizes downtime, and lithium's high rate of discharge is
perfect for a burst of power.
 Lead-acid batteries must be charged in stages over a longer time, and they
perform inefficiently during high discharge periods, making them less
versatile than their lithium counterparts.
 Along with the good safety characteristics of LFP batteries, this makes LFP
a good potential replacement for lead-acid batteries in applications of
electric vehicle
 LiFePO4 has higher current or peak-power ratings than LiCoO2
 LiFePO4 experiences much slower degradation when stored in a fully
charged state. This makes LFP a good choice for standby use.
 One important advantage over other lithium-ion chemistries is thermal and
chemical stability, which improves battery safety.

DEMERITS:

 The lithium ion battery include: Protection required: Lithium ion cells and
batteries or not us robust as some other rechargeable technology.

 They require protection from being over charged and discharged too far.

 In addition to this, they need to have the current maintainted within safe
limits.

3.1 APPLICATIONS:
 Many home EV conversions use the large format versions as the car's
traction pack. With the efficient power-to-weight ratios, high safety features
and the chemistry resistance to thermal runaway. Motor homes are often
converted to lithium ion phosphate because of the high draw.
 Active cell balancing redistributes charge during the charging and
discharging cycle, unlike passive cell balancing, which simply dissipates
charge during the charge cycle.
 Thus active cell balancing increases system run-time and can increase the
charging efficiency.
 Single "32650" LiFePO4 cells are now used in some solar-powered lights
 instead of1.2 V NiCd/NiMH.
 LiFePO4 higher (3.2 V) working voltage lets a single cell drive an LED
without circuitry to step up the voltage. Its increased tolerance to modest
overcharging (compared to other Li cell types).

CHAPTER 4

CONCLUSION AND FUTURE ENHANCEMENT

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