BMS Development

© Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
OVERVIEW OF BATTERY MANAGEMENT SYSTEM DEVELOPMENT USING

MODEL-BASED TECHNIQUES
Anthony Boon / Embed Digital Power Consultant - aboon@altair.com - 2/09/2021
AGENDA © Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
• Battery Management System (BMS) Overview

• Typical Battery Electric Vehicle (BEV) Battery Configuration
• Why BMS ?
• BMS Design Objectives
• BMS Development Hardware
• Commercial BMS integrated circuits and evaluation modules
• Battery Pack
• Microcontrollers
• BMS Configurations for Software Development using Model-based Techniques
• System Setups
• BMS Software Development
• Altair Embed and Embed DPD Integrated Development Environment (IDE)
• Design steps
• BMS Demo Diagram and code-generation
• Concluding Remarks - Advantages of Developing a BMS System with Altair Embed using Model-based
Techniques
2
BATTERY MANAGEMENT SYSTEMS (BMS)
OVERVIEW
3
TYPICAL BEV BATTERY CONFIGURATION

• The battery pack is the most critical and costly element
in modern day Battery Electric Vehicles (BEVs).
• The typical nominal DC pack voltages required in
today’s BEVs are 400V or 800V.
• Each Li-Ion cylindrical cell is typically charged to 4.2V.
• This means that 96 cells (400V) or 192 cells (800V) are
required to be connected in series.
• Cylindrical cells have a typical capacity of up to 4Ah. Types of battery cells used in BEVs
• The battery pack therefore requires many battery cells
connected in parallel, to increase the capacity while the
parallel blocks are connected in series to achieve the
required pack voltage.
• Typical BEVs have around 80 cylindrical cells connected
in parallel; which would be denoted as a 96S-80P
configuration in the 400V case.
Parallel / series connections of cylindrical
• Vehicles also have 12V and 48V battery systems for
battery cells forming a battery module as
auxiliary functions. used in BEVs
4
WHY BMS?
• The battery charger provides a single DC output voltage to
charge the battery pack at the nominal 400Vdc or 800Vdc,
depending upon the configuration.
• The charging voltage will be distributed across the series-
connected blocks of cells.
• If there is any non-uniformity among the series blocks of cells
within the pack, a non-uniform charge will be applied to the
cells. Battery modules connected together to
• Any non-uniformity of the cell voltage during charging can form a battery pack
cause a non-uniform capacity of the cells, degrading their
performance or could cause damage to the cells and
possible fire.
• Battery Management Systems (BMS) are required to monitor
and manage the battery pack to ensure safety, reliability,
optimal mileage range and maximum lifetime.
• Non-uniformity during charging can be corrected for using
cell voltage balancing.
• Other functions of the BMS include temperature monitoring
and protection and alarm reporting.
5
BMS DESIGN OBJECTIVES – PERFORMANCE OPTIMIZATION
Requirements: BMS Actions: Objectives:

• Charge/discharge cycle • Pack voltage measurement • Optimize battery pack life
optimization
• Pack current measurement • Optimize energy stored
• State-of-charge (SOC)
• Ambient temperature • Utilize maximum amount
• State-of-Health (SOH) of stored energy
• Coulomb counting (SOC)
• Adapting performance with • Maximize mileage range
• Analyze performance
temperature
(SOH)
• Optional:
• Implement battery model
• Internal resistance and analysis
• State-of-Life (SOL)
6
BMS DESIGN OBJECTIVES - SAFETY
Requirements: BMS Actions: Objectives:

• Safe and rapid charging • Cell voltage measurement • Correctly utilize available
battery capacity
• Over-voltage protection • Pack current measurement
• Maintain cell voltages
• Over-charge protection • Cell temperature
within limits
measurement
• Over-discharge protection
• Maintain cell temperatures
• Correctly distribute capacity
• Over-temperature protection within limits
to all cells within the pack
• Heat management / Cooling • Ensure an extremely
• Fusing of individual cells
system minimal risk of fire
• Thermal runaway
• Low temperature charging
management
7
BMS DESIGN OBJECTIVES – MULTI-CELL MANAGEMENT
Requirements / Issues: BMS Actions: Objectives:

• Many parallel-connected • Cell voltage measurement: • Increase battery pack life
blocks of cells connected in Cell over/under voltage
• Optimize energy stored
series strings alarms
• Utilize maximum amount
• Distribute charge uniformly • Cell temperature
of stored energy
to all cells measurement: Cell
over/under temperature
• Manufacturer mis-match of
alarms
cells
• Cell balancing
• Degradation of cell capacity
• Active
• Degradation of cell
performance over the • Passive
lifetime
8
BMS DEVELOPMENT HARDWARE
9
BMS NECESSARY FUNCTIONS AND HARDWARE

• A BMS needs to perform at least the following tasks:
• Battery pack voltage and current measurement – determine cut-off points.
• Battery ambient temperature measurement and control – optimize battery performance.
• Cell voltage measurement – ensure correctly distributed charging.
• Cell Balancing during charging – equalize the charge on individual cells.
• Cell Temperature Measurement (selected cells) – protect against heating-charging.
• Optional functions:
• Impedance measurement
• Model-based Calculations
• State-of-Charge (SOC) – coulomb counting or open-circuit voltage (model-based).
• State-of-Health (SOH) – model-based using internal impedance or discharge/charging performance.
• State-of-Life (SOL) – model-based with battery performance data over lifetime.
• Available / remaining mileage – SOC with vehicle performance data.
10
COMMERCIAL BMS INTEGRATED CIRCUITS AND DEVELOPMENT BOARDS
Texas Instruments
• bq76PL455A-q1: https://www.ti.com/product/BQ76PL455A-Q1
• 6 to 16 cells for each chip; up to sixteen chips connected in series
• 8 auxiliary analog inputs for temperature measurement
• Balancing control outputs
• 8 GPIOs, integrated comparators
• Serial UART communication
• Support for ISO26262
• Evaluation module bq76PL455EVM:
https://www.ti.com/tool/BQ76PL455EVM?utm
• On-board balancing resistors (passive)
• On-board isolated daisy-chain communication
• Up to six can be connected in series
11

Infineon
• TLE9012AQU -
https://www.infineon.com/cms/en/product/battery-
management-ics/tle9012aqu/
• 4 to 12 cells for each chip; up to 20 chips connected in
series
• Integrated balancing (150mA)
• Serial UART communication using isolated daisy-chain
• ISO26262 ASIL-C BMS
• The evaluation module TLE9012AQU_DTR_BMS2
using the Infineon TLE9012AQU chip -
https://www.infineon.com/cms/en/product/evaluation-
boards/tle9012aqu_dtr_bms2/
• On-board balancing resistors (passive) and isolated
12 daisy-chain communication.
ST
• L9963: https://www.st.com/en/automotive-analog-and-
power/l9963.html
• 4 to 14 cells for each chip; up to fifteen chips connected in
series
• Integrated balancing (200mA)
• Integrated coulomb counter
• Redundant measurements
• Serial SPI communication
• ISO26262 ASIL-D
• Evaluation module EVAL-L9963 -
https://www.st.com/en/evaluation-tools/eval-l9963.html
• 4 temperature sensing channels + current sensing
13 • Isolated SPI communication
Other Manufacturers
• NXP: MC33771B chip – FRDM33771BTPLEVB | MC33771 TPL EVB | NXP Semiconductors
• The evaluation module FRDM33771BTPLEVB using the NXP MC33771B chip –
FRDM33771BTPLEVB | MC33771 TPL EVB | NXP Semiconductors
• Analog Devices: LTC6811 chip – DC2259A Evaluation Board | Analog Devices
• The evaluation module DC2259A using the Analog Devices LTC6811 chip – DC2259A
Evaluation Board | Analog Devices
• Maxim: MAX17853 chip – MAX17853EVKIT Evaluation Kit for the MAX17853 - Maxim Integrated
• The evaluation module MAX17853EVKIT using the Maxim MAX17853 chip –
MAX17853EVKIT Evaluation Kit for the MAX17853 - Maxim Integrated
14
BATTERY PACK
• Allows a flexible setup

for the BMS software
development
• Multiple boards can be
simply connected in
series (or parallel).
• Ease of connecting
charger / loads.
• Ease of connecting to
BMS manufacturer
development boards
15
MICROCONTROLLER DEVELOPMENT BOARDS

• Altair Embed supports multiple microcontroller solutions
such as from the following manufacturers which can be
used in BMS development:
• Texas Instruments
• Infineon
• ST
• BMS diagrams can be developed for one IC manufacturer
and converted to other manufacturer’s ICs during the
development process.
• Comparisons can be made utilizing the multiple
communication ports of the microcontroller to monitor and
control battery packs with sections controlled by different
manufacturer’s development boards.
• In this design example, the TI TMS320F28379D
microcontroller was implemented with the bq76PL455EVM
also from TI.
16
BMS CONFIGURATIONS FOR SOFTWARE

DEVELOPMENT
17
SYSTEM CONFIGURATIONS FOR BMS DEVELOPMENT

Balancing
V, T
Embed GUI
Isolated UART Balancing
V, T
Balancing
High-speed UART
V, T
For initial development, the BMS evaluation boards can be directly Charger
connected to the PC and communication is performed from the GUI / Load
over the PC USB serial interface using the Embed real-time serial
communication blocks.
18

Balancing
Embed
GUI V, T
Isolated UART Balancing
JTAG V, T
High-speed UART
Balancing
V, T
Pack V, I
CAN to
external On/Off, V/I control
Charger
controllers / Load
/ devices This design example implements the bq76PL455EVM
from TI with the TMS320F28379D microcontroller
19 also from TI.

Embed Balancing
GUI Isolated UART1
V, T
Balancing
Isolated UART2
JTAG V, T
Balancing
Isolated SPI
V, T
Pack V, I
CAN to
external On/Off, V/I control
Charger
controllers It is possible to evaluate different BMS solutions simultaneously / Load
/ devices utilizing the multiple communication ports of the microcontroller
to monitor and control sections of the battery pack monitored by
20 different manufacturer’s development boards.
BMS SYSTEM SETUP

Hardware
• TI- bq76PL4455EVM
• Altair Custom Battery
board
Software
• Altair Embed
Professional
• Altair Digital Power
Addon
21
BMS SYSTEM
• Custom solutions can be developed according to customer
requirements.
• Altair Embed provides the flexible Integrated Development
Environment (IDE) in order to perform the complete set of
development tasks to achieve a final design.
Embed GUI views

Configuration with 32 series cells.
22
ADDITIONAL EXAMPLE OF A COMPLETE DEVELOPMENT SYSTEM

Embed Controller developed
GUI in Embed
Battery Pack 1 with BMS Battery Pack 2 with BMS

Bidirectional current flow emulating charger / load
23 Altair Embed / DPD is an Integrated Development Environment with many

tools to assist in the development of the controller for the battery charger.
BMS SOFTWARE DEVELOPMENT
24
ALTAIR EMBED IDE – SIMULATION ENVIRONMENT

• Block diagram environment for simulation of complex
systems
• Ideal for model-based development
• Multi-rate simulations
• Simple drag and drop interface for ease of constructing
complex diagrams
• Efficient solvers and large range of integration choices
• Extreme ease of custom block / library / user menu creation
• Ease of navigation of large diagrams
• State charts
• Frequency domain analysis
• Parameter optimization
• Further details at: https://www.altair.com/embed/
• Useful blogs at: Embed - Altair Community
ALTAIR EMBED IDE – CODE GENERATION AND EMBEDDED DESIGN

• Block diagram environment for the direct code generation of
simulated control diagrams.
• Flexible target interface block for debugging and processor-in-
loop (PIL) and hardware-in-loop (HIL) simulations.
• Full and direct support for many microcontrollers.
• Fixed / floating point arithmetic.
• Configuration of microcontroller peripherals directly in pop-up
dialogs.
• Automatic and efficient code-generation allows one to not be
concerned about the C-coding and concentrate on the
modelling and control requirements.
• Ease of implementation of external code or dll’s in the
simulation and code-generation environment if desired.
• One platform for modelling, simulation, code development,
debugging, verification and demo GUI development.
26
ALTAIR EMBED IDE – DIGITAL POWER DESIGNER (DPD)

• Large add-on to Embed for the simulation and design of
power conversion systems
• Specifically orientated to digital design techniques
• Power converter models
• Blocks for emulation of microcontroller internal peripherals
• Controllers and compensators typically used in digital power
• Sources and loads
• Frequency response analysis
• Debugging using blocks interfacing with HIL diagrams
• Tools for designing power converters
• Real-time models optimized for real-time simulation
• Battery Management System Applications
• Introductory videos at:
https://www.altair.com/resource/altair-embed-digital-power-
intro
BMS Control and Monitoring

Diagram GUI in Altair Embed
Top-level GUI
Sections:
• Battery bank values and simulation
• Configuration settings
• Control
• Summary Faults View
• Tabs for viewing specific measurements,
status, faults and logging
• General measurements view
• Cell voltages bargraph
• EVM selector.
Found at Altair  Examples  Digital Power 
Applications  BMS
28

Top-level GUI
- Configuration dialogs
29

Cell Voltages View

- with the capability to force
balancing on cells (test).
30

Cell Temperatures View
31

Faults View
- Viewing individual alarms of all
configured EVMs
32

Registers View
• Viewing the actual configuration
register values
• Viewing the actual active register
values (faults, balancing and
GPIOs).
• Viewing the actual thresholds and
analog adjustments converted to
comprehensible values.
33

Balancing Status View
34

Diagram Example in Altair
Embed
Table View
- Cell voltages and temperatures
35
BMS Control and Monitoring Diagram GUI © Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
in Altair Embed
Configuration status view:
Current GPIO status view

and control:
36

Embed
Logging of events
Measurements can be logged to
a customer selected file.
37
Step 1:
• Develop a routine included within the GUI diagram that uses the Altair Embed real-time serial
blocks for communication directly with the BMS hardware (no microcontroller required).
• The routine is developed in a way so that it is modular and sections can be code-generated to later
test in the microcontroller.
• Start with one EVM and add further EVMs to verify multi-EVM communication and monitoring.
• For safety reasons, multiple battery boards can be left unconnected at the positive end during the
Steps to BMS
software development (no series connection), thus limiting the maximum DC voltage and reducing
the risk of error.
• Use of the real-time serial blocks allows easier debugging especially during the initial phases of
Step
the2:
development.
Software • With the same routine and GUI as developed in step1, select sections of the underlying control
blocks which can be code-generated for the microcontroller and each section can be verified as
desired.
Complete
• In this step, the section monitoring the battery board is code-generated in the original diagram and
a target interface diagram is added to a new copy of the diagram, with the target interface block
simply replacing the original block that was code-generated. The BMS hardware and the
microcontroller communicate independently and concurrently with the GUI.
Development Step 3:
with Embed
• Returning to the diagram in step 1, a larger section of the underlying control blocks is code-
generated for operation in the micro-controller. In this step, the whole control and monitoring
routine is code-generated to operate in the microcontroller.
• The microcontroller communicates with the BMS hardware via the UART interface while it
communicates with the GUI over the JTAG interface using the target interface block which
substitutes the original control block.
Step 4:
• In this step a CAN bus routine is added and can communicate over the Embed PCAN blocks in the
original GUI or a new GUI.
• The CAN bus interface, if sufficiently complex, can substitute the original GUI and eliminate the
need for the JTAG interface.
• The routine can be programmed into the microcontroller flash memory at this stage and run
independently of the GUI if necessary.
38
Steps to BMS Software Development with © Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.
Embed – Step 1.
Hardware and software setup
Control, monitoring and communication diagram runs

wholly on the PC and is integrated into the GUI.
Direct connection from the PC to the EVM:
39
Embed – Step 2.
Control, monitoring and communication diagram

runs partly on the PC together integrated into the
GUI and partly on the microcontroller.
Direct serial connection from the PC to the EVM
is maintained.
Embed – Step 3.
Control, monitoring and communication diagram

runs wholly on the microcontroller. The
microcontroller communicates with the GUI.
Serial connection is now from the EVM to the
microcontroller. The microcontroller communicates
with the GUI over the JTAG interface.
Embed – Step 4.
CAN bus
Original GUI
optional
The CAN connection provides an alternative (or parallel) method to interface with
42 the control, monitoring and communication diagram running on the microcontroller.
BMS Control and

Monitoring Diagram
Example in Altair
Embed
First level with system

configuration blocks
• Dialogs directly setup the
register values according
to the configuration
parameters
• Target values of the
registers can be viewed
at this level.
43
BMS Control and

Monitoring Diagram
Example in Altair
Embed
Second level with main function
block and GUI Display interface.
• The “Routine” block is

developed in a way that it
can be later code-
generated and run on a
microcontroller while still
communicating with the
same GUI diagram.
44
BMS Control
and Monitoring
Diagram
Example in
Altair Embed
Inside the Routine block

Each section / function
is in a separate
compound block.
45
BMS Control and Monitoring Diagram Example in

Altair Embed
Serial communication control block (internally in the Comms and

46 Assign block).

Embed
To compile for the microcontroller:

Select the routine block and
choose tools  Code Gen.. The
BMS routine can be compiled for
the selected microcontroller
target.
The F28379 has sufficient RAM
to run the entire routine in RAM,
thus further easing debugging.
47

Embed
Target Interface Block can

replace the simulation block
for JTAG communication
(HIL) with the BMS
development boards.
48
ADVANTAGES OF DEVELOPING A BMS SYSTEM WITH EMBED

• The production-ready BMS firmware for the control microcontroller can be completely developed
in Altair Embed.
• Embed can also perform any required simulations for the BMS algorithms design.
• Model-based designs: battery modelling can be easily integrated using the Embed model-based
design environment.
• Routines can be easily developed and verified in groups due to the visual design environment of
Embed.
• The visual, graphical environment of Embed allows an ease of debugging routines that are
otherwise normally difficult to do so.
• The hardware demonstration in this presentation can be used to fully develop and verify the
necessary firmware.
• The system is a demonstration of Embed in use for designing a critical part of the EV system
architecture.
• Algorithms and firmware can be easily adapted in Embed to other microcontrollers and other
BMS hardware controllers.
49
BMS EXAMPLE DIAGRAMS IN ALTAIR EMBED – BMS DEMO
Further info can be found in the Altair blog on BMS systems:

Altair Embed - Using Altair Embed® to Develop a Battery Management System for Electric Vehicle
Applications - Altair Community
BMS Embed diagrams can be found in the Digital Power Designer (DPD) add-on to Altair Embed.
50
THANK YOU
altair.com
#ONLYFORWARD

BMS Development

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© Altair Engineering, Inc. Proprietary and Confidential. All rights reserved.

OVERVIEW OF BATTERY MANAGEMENT SYSTEM DEVELOPMENT USING

• Battery Management System (BMS) Overview

BATTERY MANAGEMENT SYSTEMS (BMS)

TYPICAL BEV BATTERY CONFIGURATION

BMS DESIGN OBJECTIVES – PERFORMANCE OPTIMIZATION

Requirements: BMS Actions: Objectives:

BMS DESIGN OBJECTIVES - SAFETY

Requirements: BMS Actions: Objectives:

BMS DESIGN OBJECTIVES – MULTI-CELL MANAGEMENT

Requirements / Issues: BMS Actions: Objectives:

BMS DEVELOPMENT HARDWARE

BMS NECESSARY FUNCTIONS AND HARDWARE

COMMERCIAL BMS INTEGRATED CIRCUITS AND DEVELOPMENT BOARDS

COMMERCIAL BMS INTEGRATED CIRCUITS AND DEVELOPMENT BOARDS

COMMERCIAL BMS INTEGRATED CIRCUITS AND DEVELOPMENT BOARDS

COMMERCIAL BMS INTEGRATED CIRCUITS AND DEVELOPMENT BOARDS

• Allows a flexible setup

MICROCONTROLLER DEVELOPMENT BOARDS

BMS CONFIGURATIONS FOR SOFTWARE

SYSTEM CONFIGURATIONS FOR BMS DEVELOPMENT

SYSTEM CONFIGURATIONS FOR BMS DEVELOPMENT

Isolated UART Balancing

SYSTEM CONFIGURATIONS FOR BMS DEVELOPMENT

BMS SYSTEM SETUP

Embed GUI views

ADDITIONAL EXAMPLE OF A COMPLETE DEVELOPMENT SYSTEM

Battery Pack 1 with BMS Battery Pack 2 with BMS

23 Altair Embed / DPD is an Integrated Development Environment with many

BMS SOFTWARE DEVELOPMENT

ALTAIR EMBED IDE – SIMULATION ENVIRONMENT

ALTAIR EMBED IDE – CODE GENERATION AND EMBEDDED DESIGN

ALTAIR EMBED IDE – DIGITAL POWER DESIGNER (DPD)

BMS Control and Monitoring

BMS Control and Monitoring

BMS Control and Monitoring

Cell Voltages View

BMS Control and Monitoring

Cell Temperatures View

BMS Control and Monitoring

BMS Control and Monitoring

BMS Control and Monitoring

Balancing Status View

BMS Control and Monitoring

Configuration status view:

Current GPIO status view

BMS Control and Monitoring

Control, monitoring and communication diagram runs

Control, monitoring and communication diagram

Control, monitoring and communication diagram

BMS Control and

First level with system

BMS Control and

• The “Routine” block is

Inside the Routine block

BMS Control and Monitoring Diagram Example in

Serial communication control block (internally in the Comms and

BMS Control and Monitoring

To compile for the microcontroller:

BMS Control and Monitoring

Target Interface Block can

ADVANTAGES OF DEVELOPING A BMS SYSTEM WITH EMBED

BMS EXAMPLE DIAGRAMS IN ALTAIR EMBED – BMS DEMO