BETTER BMS Functional Specifications

Introduction
During the Battery Safety Conference in Las Vegas during a discussion with
delegates it is confirmed that it must be possible to electronically recognize the
signals that precede a thermal runaway with lithium batteries. This is the basis for
developing a better BMS. This ultimately led to co-operation with CALCE (University
of Maryland) with the objective to develop a Better BMS to improve lithium battery
safety. This document describes the functional specifications that a BMS should
have to reach this objective. Furthermore, recommendations are added to improve
QC testing and warranty evaluation in e-bike battery applications, which are the
initial focus of the Better BMS development.
Better BMS concept was discussed with Prominent battery specialists & scientists
from all over the world. The Better BMS idea was received positively led to intensive
discussions -even with high end aerospace and defense organizations.

Sensors
1. Most e-bike batteries do not have enough temperature sensors to timely
recognize problems. The recommendation is to use one sensor per cell for
mission critical applications. However, for commercial applications such as e-
bikes and considering that 18650 cells from reputed manufacturers
(Panasonic, Samsung, Sony) tend to distribute heat fairly evenly one
temperature sensor per up to 5 (paralleled) cells is a proposed compromise.
For a typical 10S4P e-bike battery this means 10 sensors. It should be noted
that the cost of the sensors is very low; assembly cost is the most dominant
factor in those cases where automated assembly is not possible (typically
with irregular shapes).

2. E-bike batteries generally do not have moisture sensors, without which it

is not possible to recognize leakage of the battery pack or condensation
buildup. Two moisture sensors/pack are recommended.
 3. Accelerometers (Drop Detection) can detect if the pack is dropped by
the user. The recommendation is to use one accelerometer/pack. An
accelerometer that just detects crossing a predefined limit is inexpensive
(contrary to the types that measure the G-force exactly).BMS's with max.12
sensors, consider 1 moisture sensor.

4. Monitoring functions (in addition to basic BMS functionality). Individual

cell voltages and currents . In commercial applications such as e-bikes
it may not be viable to monitor individual cells. Monitoring groups of
paralleled cells (typically 4/5) is then the next best option.

Safety algorithms
These will determine when the battery must be checked and ultimately be
disconnected to avoid thermal runaway. In the CALCE test laboratory destructive
tests will be performed to prove the effectiveness of these safety algorithms. The
resulting proof of concept is expected by Q2/2014. The BMS must have a self-test
function (disconnect battery at BMS defect) and the BMS must also have a charge
control function and not allow multiple short time resets.
Warranty Assessment functions (in addition to basics)
Charge / Discharge cycles count preferably with initial and final SOC values.
Cumulative record of capacity charged and discharged
Registration of deep discharge dates and next charge dates
Registration of extreme temperatures encountered
First date of usage (defined as the moment where frequent charge/discharge
cycles are registered, as opposed to testing cycles),

This enables the manufacturer to detect warranty fraud (invoice claims battery is
within warranty – BMS proves different) Quality Control functions
Monitor cell (group) voltages and sensors during QC test cycle; report
irregularities
 expose a small percentage of a production batch to vibration, moisture and
temperature (High & Low), shocks. Monitor whether the battery responds
satisfactorily hereto during i.e. 1 month
Perform continuous charge/discharge cycling with repetitive peak/constant
load sequences to a very small percentage of a production batch to identify
any chemical cell issues. During 1 month this results in ~ 100 cycles. These
advanced QC functions can prevent costly recalls caused by manufacturing
faults. As detection takes place before the batteries hit the market, the cost
to correct is low, while the cost of a recall is substantial, in addition to brand
image issues.
Cost & benefits for the manufacturer
A Better BMS will add to the cost of the battery in favour of improved test-ability
and safety. While the cost of sensors is low, the assembly cost is high when this is
a manual process. Also for general quality assurance it would be best to work
towards automated assembly. Especially the ability to recognize user behaviour will
reduce the warranty cost. Deep discharging is known to be the prime cause for
warranty claims but as most BMS’s are not able to register this, the consumer gets
the benefit of the doubt (and the manufacturer suffers). When the BMS can detect
sudden deformation this also relieves the manufacturer from replacing a battery
that was subject to mistreatment (falling).
The ability to prevent recalls is a strategic choice that can save a lot of money but
this is like taking insurance at a very small premium. Moreover, the image of a
brand can be hurt badly by a recall and that may be a major reason to take
measures, even if they slightly increase production cost. Better battery safety will
be a benefit to the manufacturer’s quality image.
Conclusions
E-bike batteries have known issues with safety; often caused by a combination of a
faulty BMS and -charger, as well as warranty issues caused by user mistreatment –
which as explained above can often be detected. BMS designers are encouraged to
add sensors, the associated monitoring and incorporate a self-test function that
operates 100% independent from the BMS itself.