Advanced Battery Management System

A Seminar Report on

Advanced Battery Management System

Submitted in partial fulfillment of the requirements for the award of the degree of

BACHELOR OF TECHNOLOGY

In

ELECTRICAL & ELECTRONICS ENGINEERING

By
M Sam Moses Sastry
(17A31A0298)

DEPARTMENT OF ELECTRICAL & ELECTRONICS ENGINEERING

PRAGATI ENGINEERING COLLEGE
(Approved by AICTE, Permanently Affiliated to JNTUK, KAKINADA & Accredited by NAAC with ‘A’ Grade
1-378, A.D.B. Road, Surampalem, Near Peddapuram-533437

2017-21

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INDEX

• Introduction
• Literature Survey
• System Development
• Advantages
• Applications
• Future Scope
• Conclusion
• References

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1. INTRODUCTION

Battery Management System is an electronic system that manages a

rechargeable battery to ensure its safety and efficiency. Battery Management System is
designed to monitor the parameters associated with the battery pack and its individual
cells, apply the collected data to eliminate safety risks and optimize the battery
performance.

In India, high cost of electric vehicles (EVs) is mainly attributed to their

batteries still being imported, which incurs heavy expenses. The government has come
up with a number of policies aimed towards boosting EV manufacturing in India.

Fig 1.1 Battery Management System position

Electric vehicles (EVs) are gradually being adopted as the main-stream mode
of transport across the world. An EV consists of a battery pack, motor, power converter
and mechanical transmission system. Most EVs use lithium-ion batteries as the source
of power due to such factors as high energy density, low discharge rate and long
lifespan. Battery failure can com-promise the safety of drivers and passengers. It is
there-fore necessary to monitor every cell in the battery pack and measure crucial
information precisely. This calls for a battery management system (BMS) dedicated
entirely to protect the battery and prolong its life.

As e-mobility increasingly become part of daily life, there is a growing need for
more efficient charging solutions. Fast electric vehicle (EV) charging station equipped
with powerful DC chargers are currently the answers. DC EV chargers are an attractive

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choice because they allow much faster charging than the standard AC EV ones that
many EV owners have at home. Today, a DC charger with 150KW, can put a 200km
charge on an EV in around just 15minutes. As fast charging and battery technologies
continue to evolve and improve in the near future experts anticipate the charging time
to drop even further.

BMS in an EV comprises multiple types of sensors, actuators and controllers. It

acts as the transmission part of the electronic control unit (ECU) to allow continuous
communication between the battery pack and the ECU through standard protocols like
controller area network (CAN).

The BMS needs to be reliable and highly efficient with minimum accuracy of
1mV to 2mV. It is powered continuously from the EV’s battery itself.

Fig 1.2 Block Diagram of BMS

Hence, it must consume less power but have a high processing speed, so that
load on the battery is not too high. Also, a large memory is required to store monitored
data.

Primary function of BMS is to protect every cell. Performance of a lithium-ion

battery varies with age, hysteresis and temperature variations. To prevent this, cell
balancing and thermal management are essential, as explained below. A battery should
not be recharged or discharged above or below its permissible limits, respectively, to
avoid damage. If voltage of even one cell is unequal to others, efficiency will decrease.

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Voltage and current measurement units measure voltage and current of every cell inside
a battery pack.

The government has come up with a number of policies aimed towards boosting
EV manufacture in India. Under this, Automotive Research Association of India
(ARAI), a research and certification institute, developed an intelligent BMS ARAI
eMi4 to cater to the different types of batteries. Many start-ups are also coming up with
a focus on EVs. ION Energy, a Mumbai based start-up, provides a platform based on
software analytics and Artificial Intelligence (AI) to help Indian EV companies
manufacture their own batteries, as well as design the BMS.

With the growing sales of EVs automobile manufacturers plan to extend their
BMS production capacities. To achieve better performance of BMS, there is a need for
more research in the natural environment where effects of different weather conditions
can be checked.

While the global EV markets is rapidly gaining momentum towards the target
set by Electric Vehicles Initiative (EVI) of global deployment of 20millions EV’s by
2021. EV’s in India are beginning to gain traction. While the government’s positive
push (inform of demand incentives like subsidies) is seen as a move that will help jump-
start the EV ecosystem across the country, it is our belief that the unit economics for
the right use cases have already started making commercial sense.

India has the right talent, a promising consumer base that is pro-clean mobility,
and now the rightly demonstrated regulatory commitment- a concoction that will drive
the industry to solve specific mobility needs that are best solved by Electric Vehicles.

In order to maintain safety and efficient working of EV’s we adopt the Battery
Management System Technology.

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2. LITERATURE SURVEY
2.1 Introduction
The four main components of an EV
1. Electric Motor
2. Battery Pack
3. Power Converters
4. Mechanical Transmission System

Fig 2.1 Basic Components in Electric Vehicles

Limitations of EV: Heavy Weight, Short Trip Range, Long Charging Time and Poor
Durability Of Battery.
Advantages of EV: No Exhaust (No Greenhouse Gases, Carbon Dioxide, Nox and
PM10), No Oil Consumption, Rechargeable, Cheaper Maintenance.
BEV’s use Lithium-Ion, Lead-acid and NiMH battery, Zebra and Flow Batteries etc….

2.2 Importance of Battery

We primarily concentrate on the importance of the battery when talking about
an Electric Vehicle because it is the source of power to the EV. And these are also the
important points to consider battery as important part of EV.
1. Range of the vehicles depends almost entirely on HV Battery.
2. It is the heaviest electrical component. (25% of total weight)
3. It is also most expensive component.

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Batteries used in Telsa

“The battery that Tesla has been using, sources from Panasonic for its Model S
electric car is most likely lithium-ion with a cathode that is a combination of lithium,
nickel, cobalt and aluminum oxide. The battery industry calls this an NGA battery, and
it has been around and made by Panasonic for many years now.”
“Typically, lithium-ion NGA batteries use a combination of 80 percent Nickel,
15 percent cobalt and five percent aluminum. It is unclear what mix Telsa and
Panasonic’s battery combination is. (Anode in these traditional lithium-ion batteries are
usually a graphite combination, which acts as a host for lithium-ions.) Addition of
aluminum to NGA batteries make them more stable.”

The weight of batteries of higher capacity(60-100kWh) for electric automobiles is in

the range of 385-544kg, while the gross weight of automobiles is in the range of 2050-
3070kg.
Luxury class electric automobiles with a high basic weight, e.g., Telsa Model S (85),
demonstrated the highest energy consumption per km travelled-200Wh.km-1.

Fig 2.2 Lithium-Ion Batteries setup in EV

Lithium-Ion Batteries are currently used in most portable consumer electronics

such as cell phones and laptops because of their high energy per unit mass relative to
other electrical energy storage systems. They also have a high power-to-weight ratio,
high energy efficiency, good high-temperature performance, and low self-discharge.
Most component of lithium-ion batteries can be recycled, but the cost of material

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recovery remains a challenge for the industry. The U.S. Department of Energy is also
supporting the Lithium-Ion battery recycling prize to identify solutions for collecting,
sorting, storing, and transporting spent and discarded lithium-ion batteries for eventual
recycling and material recovery. Most of today’s PHEV and EVs use lithium-ion
batteries, through the exact chemistry often varies from that of consumer electronics
batteries. Research and development are ongoing to reduce their relatively high cost,
extend their useful life, and address safety concerns in regard to overheating.

2.3 Charging Solutions

Charging the battery is as important as choosing the right battery. Some key
driving forces are shaping and advancing the EV charging market today. One is stricter
government regulation of CO2 emissions. The target is to achieve zero emissions by
2050 in most major cities worldwide relies in part on greater EV usage and better fast
charging infrastructure. Certainly, the high pollution index in cities, detrimental to
inhabitant’s health and quality of life, is a motivation to reach this target. Zero or low
emission mobility can help stem the prevalence of air pollution related health problems,
such as cardiovascular disease and asthma.
The good news by 2025 over 100 new EVs are set to launch on the market. This
step in the direction of improved urban air quality adds pressure to develop and
implement the charging infrastructure required to accommodate additional EVs on the
road. Finally, as battery manufacturers optimize their cost structures and economies of
scale. EV battery costs are decreasing. The result is that electric vehicles have never
been more attractive to purchase.

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Fig 2.3 Charging speed increased by DC Charging.

2.3 Necessity of Battery Management System

The beauty embodied in lithium battery packs is the energy they can carry in
the required volume. High energy density of lithium batteries makes it perfect for
electric vehicles, lighter and efficient. Charging is always a concern for any EV owner
and with fast charging rate of lithium packs outshines other technologies. Lithium
charges at faster rate and reduces the refueling time of the vehicle.
Moving on to the construction of lithium cell-the chemical structure, solid electrolyte
and stable encapsulation make it suitable for applications. As the saying “every
technology stays ideal only in text book”, lithium brings a good number of constraints
and restriction in its usage.
Any organization or team outperforms when it has a best manager. Lithium batteries
with birth deficiencies need proper monitoring and control to utilize its full potential.
Thermal instability has always remained a greatest hurdle in its design and application.
The efficiency falls considerably at higher operating temperature. VRLA (Value
regulated Lead Acid) batteries still prove a good choice for low end EV’s because of
robust nature, thermal stability and nature cell balancing. Though lithium brings higher
energy density, faster charging rate, low self-discharge and longer life cycle but these
features only shine when the manager is around. Over charging is another prime
concern with lithium batteries usage therefore charge need to be closely & accurately
monitored.

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Fig 2.4 Cell Balancing in Lithium Battery

Lithium battery packs comprises of multiple cells connected in series and parallel
configuration; hence cell balancing is the important aspect for efficient in power
delivery. Imbalance cell causes internal loading of battery reducing state of charge and
increasing failure rate. Cell balancing mechanism is required for proper battery pack
operation and higher cell life. Battery management system or BMS plays the role of
manager for lithium batteries maintaining and enhancing its performance with
protection against hostile conditions to prevent irreversible failure.

2.4 Battery Management System Technology

As the name is self-explanatory, a system designed to manage and control a

battery unit for proper operation. Initial designs only incorporated protection
components i.e., fuses, FET switches with analog comparators sensing deviation and
pulling the completely battery unit down in case in an abruption. With due of course of
time, lithium batteries found application in electronic, storage system, power backup
system and need of more sophisticated BMS arouse rapidly. A modern BMS comprises
of multiple blocks integrated together to build a complete lithium battery unit:
1. Power Delivery Unit (PDU), comprises of FET switch and gate driver circuit
which control the outgoing and incoming power in the battery. Cell balancing
with individual current bypass FETs are also part of the PDU. Few specific PDU
also manages regenerative braking power.

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2. Sensing and measurement, comprises of on chip or external ADCs to compute

cell voltages, junction temperature and charge/discharge current. SAR based
ADC provide high sampling rate and resolution. Modern BMS chip have SAR-
AC based AFE integrated in it.
3. Communication block, comprises of CAN transceiver, for communicating with
parallel battery packs or with the vehicle control unit.
4. Central processor manages the above blocks with embedded algorithm taking
decision as per inputs and battery state. It also manages and internal
communication of BMS.
To make a best lithium battery pack we need to just manage its voltage, current &
temperature and this is what a BMS does. Loading is critical aspect of battery
technology and managing the power deliver becomes the prime task of the BMS.
Constant load as in case of electronic devices, power requirement is rather uniform and
never stresses the BM and the battery.

Fig 2.5 Schematic diagram of BMS

Electric vehicles are non-uniform load or to be precise an erratic loading system,

where battery needs control over the power delivery. BMS acts as power controlling

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unit preventing sudden abruption in load current to affect lithium cells. Further, the
loading transients’ range in milliseconds and require an effective management to avoid
high discharge rate.
Electric vehicle is a subset of the vehicle therefore needs a fuel gauge. Coulomb
counting, a party of BMS precisely measure the state of charge and compute the driving
range. This mitigates the range anxiety of any EV owner. Further, refueling or
recharging battery bank from any charging stations requires BMS integrated battery
unit for information exchange with the charger. It is because of BMS, you can refuel
your vehicle with same rate and efficiency at any public charging station.

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3. SYSTEM DEVELOPMENT

3.1 Introduction

BMS in an EV comprises multiple types of sensors, actuators and controllers. It acts as

the transmission part of the electronic control unit (ECU) to allow continuous
communication between the battery pack and the ECU through standard protocols like
controller area network (CAN).

Primary Functions of BMS for Electric Vehicles

1. Safety
2. Performance Optimization
3. Health Monitoring and Diagnostics
4. Communication

3.2 Functions of BMS:

Safety: The Battery Management System continuously monitors parameters such as

temperature, voltage and current in and out of the pack to ensure it is being operated in
safe conditions the entire time. BMS can adjust cooling and triggering other safety
mechanisms to cease operations and minimize the risk.

Performance Optimization: Li-ion batteries perform best when their State of Charge
(SoC) is maintained between the minimum and maximum charge limits defined in the
battery profile. Cell balancing is needed to maintain the cells at equal voltage levels and
maximize the capacity utilization of the battery pack. BMS performs cell balancing by
draining excess energy from cells that are more charged than others. Through active or
passive balancing techniques

Health Monitoring and Diagnostics: The BMS uses the collected data points
(temperature, voltage, current etc..,) to estimate the State of Charge and State of Health
(SoH) of the battery pack. The SoC refers to available energy in the battery and
determine how far the vehicles can go before needing to recharge. The SoH measures

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the current condition of the battery as compared to its original capacity and indicates
the battery’s suitability for the application.

Communication: The BMS is responsible for communicating with other ECU

(Electronic Control Unit) in the vehicle. It relays the necessary data about the battery
parameters to the motor controller to ensure smooth running of the vehicle. In case of
AC charging, BMS communicates with the onboard charger to monitor and control the
charging of the battery pack.

Fig 3.1 Basic components in BMS

Primary function of BMS is to protect every cell. Performance of a lithium-ion battery

varies with age, hysteresis and temperature variations. To prevent this, cell balancing
and thermal management are essential. A battery should not be recharged or discharged
above or below its permissible limits, respectively, to avoid damage. If voltage of even
one cell is unequal to others, efficiency will decrease. Voltage and current measurement
units measure voltage and current of every cell inside a battery pack. Battery life also
gets improved if a deep discharge is avoided, BMS has a dedicated lithium-ion protector
to ensure proper charging and discharging.
If the battery is exposed to exposed to extremely high or low temperatures, it will
negatively impact performance. For lithium-ion battery, measured cell temperatures
should lie between 25˚C and 40˚C. The preferred thermal system for battery cooling is
liquid cooling. The temperature control unit measures temperature of the battery and
coolant.

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Another important function performed by BMS is energy management, this includes

state of availability power (SOP), state of charge (SOC), state of life (SOL) and state
of health (SOH) estimation. SOC is used to know the remaining power of the battery.
The balancing control unit equalises SOC of the cells in battery packs. SOH indicates
the age and expected life cycle of the pack. The digital output the displays balancing
work indicator failure alarm along with SOC and SOH.

3.3 Battery Management System IC

Analog Devices and Volvo Cars have announced that Volvo Cars first pure
electric SUV-the Volvo XC40 Recharge-will feature ADI’s integrated circuits (ICs)
that support the battery management system (BMS) and Automotive Audio Bus (A2B).
By saving vehicle weight and maximising range, these advanced technologies deliver
an attractive total cost of ownership for electric vehicles while also supporting a
sustainable future.

Fig 3.2 The Volvo XC40

“The BMS performance is critical to the electric XC40 Recharge delivering on its
promise of a silent-but-powerful, carbon emission-free, safe driving experience,” said
Lutz Stiegler, Solution Manager Electric Propulsion at Volvo Car Corporation. “An
extraordinarily high level of thought and research went into every single aspect and
component in our first pure electric SUV to ensure more miles per charge, longer
vehicle life and peace of mind while lowering the cost of ownership.”

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ADI’s ICs provide accuracy over the life of the vehicle that significantly increases miles
per charge and is scalable across the vehicle fleet from hybrid vehicles to fully electric
vehicles. The ICs meet the highest global security standards and scale across multiple
battery chemistries, including the zero-cobalt chemistries such as lithium iron
phosphate (LFP) that support social and environmental sustainability.
Electric vehicles are the future of Automotive and the market is growing significantly
with up to 10 million fully electric vehicles per year expected by 2025,” said Patrick
Morgan, Vice President, Automotive at Analog Devices. “We are committed to
continuing delivering innovative technologies with all of our collaborators that lead the
Automotive industry to a sustainable future.

Fig 3.3 Battery Management System IC

By saving electric vehicle weight and maximising range, this battery management
system IC can deliver an attractive total cost of ownership for electric vehicles while
also supporting a sustainable future.

3.4 Advanced Battery Management System

Maxim’s unique BMS technology, including MAX17843, has the industry’s only
single-chip solution to achieve ASIL D compliance.

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Fig 3.4 MAX17843 Battery Management System.

San Jose, CA and Las Vegas, N-January 9, 2018-Automotive OEMs can enhance the
safety of their lithium-ion battery packs with robust communications, comprehensive
diagnostics, and lower system costs with the MAX17843 12-channel, high-voltage
smart sensor data acquisition device from Maxim Integrated Products, Inc. Electric
vehicles (EVs), hybrid EVs, and plug-in hybrids rely on large lithium-ion battery packs
filled with hundreds or even thousands of individual battery cells. With industry experts
predicting that 25% of cars sold by 2025 will have electric engines, automotive OEMs
and Tier 1s need an intelligent battery management system to enable safe, low-cost
solutions with robust communications.

Fig 3.5 MAX17843

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Maxim is enabling a safer, smarter car of the future with the MAX17843 battery
management system (BMS). MAX17843 meets the highest safety standards, adhering
to ISO 26262 and ASIL D requirements (also applicable for ASIL C). Its differential
universal asynchronous receiver/transmitter (UART) using capacitive isolation reduces
bill of materials (BOM) costs and failure in time (FIT) rates. With this, designers can
save up to 90% of their isolation BOM cost. The UART, with ultimate flexibility,
enables robust communications in noisy environments.
Using Maxim’s unique proprietary daisy-chain architecture and successive-
approximation register (SAR) Analog-to-Digital converter (ADC), the MAX17843
captures fast, accurate voltage measurements and delivers high EMC performance. It is
applicable for a variety of automotive and EV powertrain applications.

Key Advantages
Safety: ISO 26262 and ASIL D certification, as well as TUV certification in design and
management process; meets various BCI requirements; comprehensive diagnostics
Low System Cost: Internal cell balancing and UART reduces BOM costs compared to
competitive solutions; only IC to allow capacitive or transformer isolation
January 9, 2018
Robust Communications: Reliable distributive and centralized CMC architecture with
UART; Supports 100m daisy-chain segments and high noise immunity; Supports
emission, ESD, and hot plug.

3.5 Wireless Battery Management System

Analog Devices, Inc has introduced a wireless battery management system (wBMS),
which provides automotive manufacturers with increased flexibility to scale their
electric vehicle fleets into volume production across a wide range of vehicle classes.
The wBMS eliminates the traditional wired harness, saving up to 90 per cent of the
wiring and up to 15 per cent of the volume in the battery pack, as well as improving
design flexibility and manufacturability, without compromising range and accuracy
over battery life.

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Fig 3.5 Wireless Battery Management System

Integrated system functionalities

The wBMS includes all ICs, hardware and software for power, battery management,
RF communication and system functions in a single system-level product that supports
ASIL-D safety and module-level security. By delivering high accuracy for the vehicle
lifetime, the system enables maximum energy use per cell required for best vehicle
range and supports safe and sustainable zero-cobalt battery chemistries, such as lithium
iron phosphate (LFP).
“The transition of battery packs from wired to wireless connectivity enables automotive
manufacturers to scale their electric vehicle platforms across multiple vehicle models
to meet growing consumer demand,” said Patrick Morgan, Vice President, Automotive
at Analog Devices.

Fig 3.6 Wireless BMS

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“Our wBMS solution not only simplifies manufacturing but also allows new systems
to be built on wireless data, accelerating the entire industry towards a sustainable future.
We are honoured to bring this breakthrough system innovation to market with General
Motors.”
Additional system features enable batteries to:
• Measure and report performance
• Detect failures detection
• Optimise battery pack assembly.
The obtained data can be monitored remotely throughout the battery lifecycle – from
assembly to warehouse and transport through installation, maintenance and into a
second-life phase.
ADI and General Motors have announced a collaboration, bringing the wBMS
technology to General Motors’ Ultium battery platform. This will facilitate widespread
electrification of the automotive company’s fleet.

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4. ADVANTAGES

1. Maintains battery in a state in which it can fulfill its functional design

requirements.
2. Protects the safety of the battery-operated device’s and detects unsafe operating
conditions and responds.
3. Protects cells of battery from damage in abuse/failure cases.
4. Prolongs life of battery (normal operating cases).
5. BMS is to keep track of the state of charge (SOC) of the battery.
6. Simple in Coulomb counting.
7. Simple and easy to predict capacity fade and internal resistance increment

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5. APPLICATIONS

Battery Management Systems (BMS) are used to monitor and control battery banks
used in many industries. With a dominance of Lithium Ion (Li-Ion) batteries in most
energy storage applications, BMS have become the critical enabler, from both a
functionality and safety perspective.

• Electric Vehicles, which includes electric cars, trucks, and non-road type
vehicles such as golf carts, as well as electric-powered machinery such as fork
lifts. Typically, battery banks within the forklift, car and bus, communicate
with the Battery Control Module using CAN
• Grid Power infrastructure where battery banks are used for backup power or to
protect from power fluctuations on the grid. Applications include cell phone
towers, A/C power substations, Internet infrastructure equipment, aviation
ground support systems, tower communications and weather stations, plus
Distributed Energy Resources. The latter application is a sizeable industry itself,
encompassing solar and wind-generating plants.

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6. FUTURE SCOPE

The BMS optimization algorithm could be further improved by considering the

cost of each charge of each cell as a techno economical and discharge cycle of battery
to prevent excessive activities that could shorten the battery life.
Algorithms can be developed to predict power usage and generation in the
microgrid, such algorithms can be integrated with optimization-based power flow
control method for real time energy management in the microgrid.
New transmission capacity and better operating practices, such as greater
automation controller, forecasting, renewable energy visibility, and transmission
planning methods, market integration and implementation of smart energy management
systems can resolve the problems and challenges for grid operators, often
circumventing the need for curtailment.

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7. CONCLUSIONS
Advanced BMS can significantly improve the performance of EVs. Adaptive
mathematical models are an efficient tool for improving and refining BMS. The State-
of-Charge determination algorithms, developed with the help of adaptive battery
models, are highly precise and represent a good basis for practical implementation.
BMS is a critical component of electric vehicles. That promotes guarantee
safe, efficient and reliable battery operation. The combination of advanced charging
algorithms and adaptive S BMS improves the battery functioning thus improving the
characteristics of EV.
With the growing sales of EVs, automobile manufacturers plan to extend their
BMS production capacities. To achieve better performance of BMS, there is a need for
more research in the natural environment where effects of different weather conditions
can be checked. Improve the three main primary concerns in DC fast charger
architecture are how to minimize the cooling effect, deliver high power density, and
reduce overall system size.
India has the right talent, a promising consumer base that is pro-clean mobility
and now the rightly demonstrated regulatory commitment- a concoction that will drive
the industry to solve specific mobility needs that are best solved by EVs

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8. REFERENCES

[1].
Battery Management System in Electric Vehicles by Ayush Sharma in Electronics
for You (Efy) Magizine.

Electrical India Magazine, Infineon Technologies Article on “Fast Charging in

[2].

EV’s”.

[3].
Advanced Trends Electric Vehicles in www.evreport.com

“Battery Management Systems for Electric Vehicles using Lithium-Ion Batteries”

[4].

by V Vaidessan, S Bhwavesh and M Devasena in IEEE on March 2019.

W. Taylor, G. Krithivasan, and J. J. Nelson, “System safety and ISO 26262

[5]

compliance for automotive lithium-ion batteries”.

M.A.Hannan, M.H.Hoque, S.E.Peng,andM.N. Uddin,‘‘Lithiumion battery

[6]

charge equalization algorithm for electrical vehicle applications”.

[7]
Sandeep Dhameja. Electric Vehicle Battery Systems. Butterworth Heinemann.

[8]
David Linden, Thomas B. Reddy. Hand Book of Batteries

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