As presented to

July 2009
Battery Management
Systems for Electric
Vehicles
Comparison:
Lead vs. Lithium in EVs
 Charging
 Lead-acid batteries charges well in a long string
 Over voltage in a cell is not good, but generally passes the current to the
next cell in an equalization cycle with little damage.
 Cell balancing can be done with a sophisticated charger (IUIa cycle)
 Lithium batteries OK in a string, but over voltage on a individual cell can
do serious cell damage.
 Individual cell charging is solution, or
 Balancing cells and charge in a string.
 Discharging
 Lead can tolerate discharging to 0% State of charge (SOC) with some
cycle life damage.
 Lithium will have serious damage when discharging below 2.0V, can be
completely ruined.
Lead-Acid Discharge Curve
6V Lead Acid Battery Discharge Curve

6.5

6.4

6.3

6.2
Battery
Voltage
6.1

5.9

5.8

5.7
110 100 90 80 70 60 50 40 30 20 10 0

State of Charge
http://www.trojanbattery.com/BatteryMaintenance/Testing.aspx
 Lithium Discharge Curves

 Lithium Batteries have a fairly flat discharge curve with

sharp shoulders
http://enerdel.com/content/view/105/88/
Lithium BMS Challenges
1. Must not Over-Charge an individual cell
2. Must not Over-Discharge an individual
cell
3. Must not let cells get too hot during
charge or discharge
ENTER THE LITHIUM BMS
 Many thoughts and discussions on what constitutes a Battery
Management System (BMS):
 Monitor and Detect Cell Over-Charge, and cut off charger
 Monitor and Detect Cell Over-discharge and alert operator, or cut off
system power.
 Cell Balance for string charging
 Temperature Monitoring
 Remaining State of Charge determination
 This is done in your cell phone & laptop, why not in your car?
 High voltages and high currents make it difficult

 Sparse BMS technology availability has held up Lithium

conversion projects.
BMS Topology: Distributed
 Put voltage monitor and
discharge balancer on
each cell, with digital
communications for
charger cutoff and status.

Advantages: Simpler design and construction and its potential for higher
reliability in an automotive environment.
 
Disadvantages: Large number of mini-slave printed circuit boards which are
needed and the difficulty of mounting them on some cell types.
BMS Topology: Modular

 Several Slave
controllers
consolidate data
to a master

Advantages: Does not need printed circuit boards connected to individual

cells.

Disadvantages: Master-Slave isolated communications can be challenging in

an EV.
BMS Topology: Centralized

 Centralized 1

Master Control Central

Unit Master
Control Unit

Advantages: Single installation point. No complex inter-vehicle communications

Disadvantages: Typical EV batteries are distributed in the vehicle, requiring

wiring to a central location.
Single source for balancer heat generation.
Li-Ion BMS Market options
 Investigate BMS solution for highway capable
EV conversion
 Needs to support typical DC system:
 160 AH prismatic LiFeP04 (3.2V),
 250A + systems
 40-48 cells (128 to 153 volts)
 Must monitor
 Should manage, report and balance
 Li-Ion BMS options

Temper. (6)
No of cells

Protection
Over Volt
Company

Topology

Display

Comm.

48-cell
gauge (8)
Balan.

Price,
Case
(10)

(11)
(1)

(3)

(4)

(5)

(9)
Fuel
Agni Distri 1~200 ✓ - - - - Wire - ~$1000
motors b.
Stybrook
Ltd
Black Mod 4~any ✓ ✓ - ✓ ✓ Seria Plastic / ~$2200
Sheep ular l metal
Technolo
gy
Elithion Distri 1~255 ✓ ✓ ✓ ✓ ✓ Wire - ~$2000 -
b. CAN $4000
RS23
2
EV power Distri 1~any ✓ - - - ✓ Wire Metal ~$1800*
b.
Li-Ion BMS options (continued)

Temper. (6)
No of cells

Protection
Over Volt
Company

Topology

Display

Comm.

48-cell
gauge (8)
Balan.

Price,
Case
(10)

(11)
(1)

(3)

(4)

(5)

(9)
Fuel
High Tech Distri 1~any ✓ ✓ ? - ? Wire - ??
Systems b.
(SSI?)

Ningbo Mod Up to ✓ ✓ ✓ ✓ - ? Metal $1789

Yangming ular 50,
Elite higher
Power available
(BMS 50)
PackTrakr Mod 6~40 - ✓ ✓ - - RS23 Plastic $710 (40
from ular 2 cells
KJHall only)
Motor Co
REAP Mod 4~168 ✓ ✓ ✓ ✓ ✓ Bus - 697 x 4 =
systems ular $2788*

Volt Distri 1~any ✓ - - - opt Opt - $864-

Blocher b. wire 1008
assemble
d
BMS Honorable Mention
 Lithium Balance – No published specs or pricing
 Gary Goodrum – DIY BMS Ckt, 24 cell on Endless
Sphere, Low current device for bikes
 Metric Mind – Custom BMS, no pricing for BMS products
 Boundless – creates custom battery packs.
 Hot Juice Electric BEQ – Balance only
 Manzanita Micro – Partial solution, 4 cells for $250
 Open Source BMS projects – no resolutions
Small Print:
1. Company: A few other companies are getting ready to offer Li-Ion BMSs, but are not yet ready to be listed here.
2. Class:
• Simple: analog technology, just able to detect that some cell's voltage is too low or too high
• Fancy: sophisticated digital technology, able to measure and report every cell voltage, and to calculate SOC
3. Topology: See previous slides
4. Number of cells: this is the acceptable range in the number of cells in series. The number of cells in parallel does
not matter.
5. Balance: The BMS is able to remove energy just from the most charged cells, to allow the other cells to reach the
same level of charge.
6. Temperature: The BMS is able to measure and report individual cells' temperature.
7. Current sense: The BMS includes a current sensor or at least an input for a current sensor, to measure battery
current. This enables the BMS to react to excessive current, and to calculate the SOS or DOD.
8. "Fuel gauge": a.k.a.: "Gas Gauge". The BMS calculates the SOC (State Of Charge) or DOD (Depth Of
Discharge), by integrating the battery current.
9. Communications:
• Wire: separate wires are used, each with a single, specific function, such as to turn on the charger relay.
• CAN: CAN bus, common in vehicles and European industrial equipment.
• RS232: serial point-to-point communication, usually used only for initial set-up and testing, but some time also
available for communication during operation.
10. Case: Whether the BMS controller is enclosed (metal or plastic case), or it is an open PCB assembly. Unless
otherwise noted, any cell-mounted boards are assumed to be open PCB assemblies.
11. Price: from manufacturers' websites or discussion with their clients.
Hardy EV Flex BMS
 Centralized BMS Architecture
 Miniature In car display and operator alerts
 Battery monitoring for over-voltage, under voltage
 3 versions in production
 Up to 36 cells - For NEVs and small EVs
 Up to 48 cells – For DC systems
 Up to 84 cells – Prius plug-in conversions and AC systems
 Temperature monitoring
 Adjustable voltage and temperature thresholds
 Cell balancing with built-in thermal management
 Full diagnostic self test identifies faulty wiring
 Internal Log allows identification of problem batteries
 USB Log Option for detailed cell monitoring logs
 Current monitor option for state of charge determination
 Works with charger up to AC: 25A 240V
 Priced for EV conversions: $891 for 48 cell system
 Data logger option $50
 Current Monitor option $60

 www.ConvertTheFuture.com
Contact Information

Mark Hardy
Hardy EV, LLC

Hardy.Mark@ConvertTheFuture.com

ConvertTheFuture.com

858-775-6275