BMS Design

Designing a Battery Management System (BMS) for a 3S (3 cells in series)

lithium-ion battery with specific operating conditions requires careful selection
of components to handle high current loads, low temperatures, and precise
charging conditions.
1. Key Design Specifications
• Battery Pack Configuration: 3S1P
• Nominal Voltage: 4.15V * 3 = 12.45V
• Capacity: 80Ah
• Operating Temperature: Down to -50°C to +45°C.
• Current Tolerances:
o 1000 A for 0.25 seconds
o 650 A for 0.25 seconds
o 500 A for 5 seconds
o 400 A for 5 seconds
• Charging Regimen: Constant Voltage (CV) and Constant Current (CC) at
12.45V, with current tapering to 1 A as it reaches full charge.
2. High-Level Requirements
• High Current Tolerance: Your BMS must withstand momentary currents
up to 1000 A. Ensure the components, such as FETs and PCB traces, are
rated accordingly.
• Low-Temperature Operation: Components should function reliably
down to -50°C to +45°C. Many commercial-grade components do not go
this low, so you'll need to select parts rated for extreme environments.
• Overcurrent, Overvoltage, Undervoltage Protection: Include circuits to
protect against faults.
• Thermal Management: Current loads like 1000 A generate significant
heat. Ensure the design has adequate heat dissipation or management.
3. Component Selection
A. Battery Protection ICs
• BQ76930/BQ76940 from Texas Instruments: Suitable for multi-cell
configurations (up to 10 series cells) with integrated cell balancing and
protection features.
• ISL94212 from Renesas: A robust BMS IC with features like overcurrent,
short circuit, and cell balancing, rated for extreme temperatures.
B. High-Current MOSFETs
• Use MOSFETs with low Rds(on) (on-resistance) to handle high current
efficiently and minimize heating. Look for MOSFETs like IRLB3034PBF or
 IXYS IXFN80N50 that can handle up to 1000 A in short bursts and have
low thermal resistance.
• Ensure proper heatsinking and layout to manage heat dissipation.
C. Current Sensors
• Use Hall-effect current sensors (e.g., Allegro ACS758) for high-current
monitoring with accuracy and isolation. These sensors can operate in
extreme temperatures and give reliable current readings for protection
circuits.
D. Temperature Sensors
• For extreme environments, consider thermistors rated for -50°C (e.g.,
Panasonic ERT series or TE Connectivity thermistors).
• Place thermistors near cells and MOSFETs to monitor temperature in real
time.
E. Passive Components
• Balancing Resistors: Use low-resistance, high-power resistors for passive
cell balancing.
• Capacitors: Use high-quality, low-ESR capacitors rated for your voltage
requirements and extreme temperatures.
• PCB Layout: Use wide copper traces or copper bars for high current
paths to prevent overheating.
F. Microcontroller (MCU)
• An MCU such as the STM32 series from STMicroelectronics or PIC18
series from Microchip can manage control functions, data logging, and
communication.
• Select an MCU rated for low temperatures and include EEPROM or FRAM
for data logging.
G. Power Supply Circuit
• Design a DC-DC converter to power your BMS circuit from the main
battery pack voltage, ensuring it operates within extreme temperatures.
4. Protection Circuit Design
• Overcurrent Protection: Use the current sensor data to disconnect the
load via MOSFETs when the current exceeds thresholds.
• Overvoltage/Undervoltage Protection: Set voltage limits in the BMS
firmware to disconnect charging or discharging when cell voltages go
beyond safe levels.
• Thermal Protection: Monitor cell and component temperatures and
trigger a shutdown or derate current if they exceed safe operating limits.
5. Charge Control (CV and CC)
 • Constant Current (CC): Design the charger to provide a controlled
current (initially at the max safe charging rate) until the voltage reaches
the target level (12.45V).
• Constant Voltage (CV): Once the pack reaches 12.45V, hold this voltage
and allow the current to gradually drop until it reaches 1 A. Integrate this
with your BMS control using an MCU or dedicated charging IC that allows
CC/CV profiles.
6. PCB and Thermal Management
• Thick Copper PCB: Use a 4-layer PCB with thick copper (up to 2 oz or 3
oz) for high-current paths.
• Thermal Pads and Heatsinks: For MOSFETs and high-power components,
ensure adequate heatsinking and use thermal pads or vias to improve
heat dissipation.
• Conformal Coating: To withstand -50°C to +45°C, use a suitable
conformal coating to protect the PCB.
7. Testing and Calibration
• After assembly, perform testing under load to verify overcurrent, thermal
protection, and charge/discharge performance.
• Temperature testing at low extremes (down to -50°C to 45°C) will ensure
that components function as expected.
By using components rated for high current and extreme temperatures,
ensuring adequate thermal management, and designing with safety margins,
you can build a BMS that is robust, safe, and effective for your 3S battery pack.

SIMULATION

To simulate a complex Battery Management System (BMS) with all the

components listed (MOSFETs, current sensors, temperature sensors,
microcontrollers, and more), you’ll need software that supports both circuit
simulation and embedded programming. Here are some options with details on
their capabilities for your project:
1. LTspice (Analog Devices)
• Best For: Power electronics, basic analog circuitry.
• Features: LTspice is a free tool particularly suited for simulating
MOSFETs, capacitors, resistors, and basic control circuits.
• Limitations: LTspice does not support MCU simulation or detailed
thermal analysis. You would use it for initial circuit-level tests (like
overcurrent and voltage protection circuits).
• Use Case in BMS Design: Good for modeling the power electronics (e.g.,
MOSFET switching, current and voltage sensing circuits).
2. PSIM (Powersim)
• Best For: Power electronics, battery management, and motor control.
• Features: PSIM offers dedicated modules for battery simulation, thermal
management, power electronics, and digital control. Its “SimCoder”
module can help design and test embedded control algorithms.
• Limitations: Limited MCU simulation and sensor model library, but it
works well for high-power circuits, such as simulating MOSFETs under
high current loads and extreme temperatures.
• Use Case in BMS Design: Use PSIM to simulate battery pack behavior
under load, protection circuit response, and thermal performance.
3. MATLAB Simulink (MathWorks)
• Best For: Advanced BMS modeling, control systems, and embedded code
generation.
• Features: MATLAB Simulink has specialized toolboxes like Simscape for
simulating physical systems, SimPowerSystems for power electronics,
and Battery Management Systems Toolbox for simulating and optimizing
BMS algorithms.
• Advantages: It can model everything from high-current switching and
thermal effects to embedded control algorithms (with blocks for
MOSFETs, sensors, etc.).
• Limitations: Requires a steep learning curve and can be resource-
intensive.
• Use Case in BMS Design: Use MATLAB Simulink for complete end-to-end
simulation: testing current sensing, control algorithms, charge
management, and thermal protection.
4. PSpice (Cadence)
• Best For: Mixed analog and digital circuit simulation.
• Features: PSpice includes a large component library, supports complex
mixed-signal simulations, and can model the behavior of MOSFETs,
current sensors, and passive components in detail.
• Limitations: Doesn’t natively support full BMS or battery cell models.
However, Cadence provides battery modeling through OrCAD Capture,
allowing you to create custom cell models.
• Use Case in BMS Design: Use PSpice for circuit-level simulation of power
electronics, overcurrent and overvoltage protections, and to verify
MOSFET and sensor behavior.
5. Altium Designer with Altium CircuitStudio
• Best For: PCB design with some basic circuit simulation capabilities.
 • Features: Altium provides advanced PCB layout capabilities and
integrates with SPICE for basic circuit simulation. It’s ideal for high-
current trace layout and PCB thermal management.
• Limitations: Not designed for detailed BMS simulations or embedded
software testing, but it’s highly effective for layout design and board
thermal analysis.
• Use Case in BMS Design: Use Altium for designing the physical PCB
layout, ensuring appropriate trace thicknesses, and checking thermal
distribution.
6. Proteus (Labcenter Electronics)
• Best For: Embedded systems and mixed-signal simulation, including MCU
programming.
• Features: Proteus allows you to simulate circuits and microcontrollers
together, supporting a range of MCU architectures (e.g., PIC, STM32). It
has a good library of components and sensors.
• Limitations: Less detailed for high-current or thermal simulations, but
strong for embedded system testing.
• Use Case in BMS Design: Ideal for testing embedded code for
current/temperature monitoring, sensor handling, and control
algorithms.
Recommended Approach for Simulation Workflow:
1. Power Electronics Simulation: Start with LTspice or PSIM to simulate
power components like MOSFETs, resistors, and capacitors. This will
allow you to test high-current paths and thermal characteristics.
2. System-Level Control & Embedded Simulation: Use MATLAB Simulink
for creating control algorithms and embedded code for the BMS.
MATLAB’s Battery Management Toolbox is ideal for simulating
charge/discharge cycles and protection mechanisms.
3. PCB Layout and Thermal Analysis: Use Altium Designer for designing
your PCB, focusing on trace thicknesses for high currents and ensuring
the layout is optimal for heat dissipation.
4. Embedded Control Testing: Use Proteus to test and verify MCU firmware
that handles current sensing, temperature management, and voltage
cut-offs, allowing you to simulate real BMS behaviors.

PROCESS TO DRAW IN LTSPICE

Creating a BMS in LTspice with your specific requirements (3S configuration,

high current tolerances, temperature operation at -50°C +45°C, and CC/CV
charging control) involves a detailed setup. I'll guide you step-by-step,
specifying how to implement each function in LTspice.
1. Specifications Recap
• 3S1P Configuration: 3 cells in series, each at 4.15V, giving a total of
12.45V.
• Current Tolerances:
o 1000A for 0.25s
o 650A for 0.25s
o 500A for 5s
o 400A for 5s
• Operating Temperature: -50°C to +45°C
• Constant Voltage (CV) and Constant Current (CC) Charging: Voltage up
to 12.45V, current steps down to 1A.
• Battery Capacity: 80Ah

Step-by-Step LTspice Setup

1. Open LTspice and Create a New Schematic
o Start a new schematic to lay out your BMS circuit.

Step 2: Simulate Battery Pack

• Voltage Sources for 3S Setup:
1. Press F2 to open the component library.
2. Choose Voltage (a voltage source) and place three voltage sources
in a series configuration to represent each cell.
3. Connect the positive terminal of one source to the negative
terminal of the next to create a 3-cell series.
4. Right-click each voltage source to set the DC voltage to 4.15V.
• Label the terminals:
o Label the top positive terminal as “Battery+” and the bottom
negative terminal as “Battery-” for reference.

Step 3: Current Sensor (Shunt Resistor)

• Adding a Shunt Resistor:
1. Press F2 and choose Resistor.
2. Place the resistor between Battery- and ground.
3. Right-click on the resistor and set the value to 0.001 ohms (low
enough to measure high currents with minimal voltage drop).
4. Label it as Current Sense Resistor.

Step 4: Add MOSFET for Overcurrent Protection

 • MOSFET Switch:
1. Press F2 and search for an nmos transistor to use as a high-power
MOSFET.
2. Place it in series with Battery+ (before it connects to any loads or
further circuit components).
3. Right-click to adjust the MOSFET parameters for high current if
needed, or choose a model with low Rds(on) to handle high
currents.
• Connect the MOSFET:
o Connect the drain (D) of the MOSFET to Battery+.
o Connect the source (S) of the MOSFET to the output side of the
battery.
o Leave the gate (G) unconnected for now; we’ll connect it to the
control circuit later.

Step 5: Overcurrent Protection Circuit

• Use a Comparator to detect high currents through the shunt resistor:
1. Add an Op-Amp from the component library.
2. Set up the op-amp as a comparator by connecting the non-
inverting input (+) to the voltage across the shunt resistor.
3. Connect the inverting input (-) to a reference voltage that
represents your current limit (calculated from Ohm’s law: V=IRV =
IRV=IR with R = 0.001 ohms).
4. Output of the comparator goes to the gate of the MOSFET to turn
off if overcurrent is detected.

Step 6: Temperature Simulation

• For the operating temperature of -50°C, we simulate the thermal
properties in LTspice by adjusting component temperature parameters.
• Setting the Simulation Temperature:
o Go to Simulation > Control Panel in LTspice.
o Under the Temperature tab, set the operating temperature to -
50°C.

Step 7: Voltage Monitoring and Divider

• Voltage Divider Circuit:
1. Use two resistors in series between Battery+ and ground to
reduce the 12.45V to a safe measurement level.
2. For example, set R1 = 10k ohms and R2 = 2k ohms.
 3. Take the output voltage between R1 and R2 and label it as
Voltage Monitor.

Step 8: Constant Current (CC) and Constant Voltage (CV) Charging Circuit
• Current Source:
1. Press F2, choose Current Source, and set it to provide an initial
charging current of 1A.
2. Place the current source at Battery+ to simulate the charging
process.
• Voltage Limiter for CV Mode:
1. Use a Zener Diode (find it in the component library under Diodes).
2. Set the Zener voltage to 12.45V.
3. Place it in parallel with the battery pack to prevent overcharging
(it conducts if the battery voltage exceeds 12.45V).

Step 9: Add Ground and Complete Wiring

• Add a Ground:
1. Press G and place the ground symbol.
2. Connect it to all ground points, especially the negative side of the
current sense resistor and the battery terminals where needed.

Step 10: Run the Simulation

1. Add Probes for Monitoring:
o Place voltage and current probes (click on wires where you want
to measure values).
o Monitor the Voltage Monitor point and current across the shunt
resistor.
2. Set Up the Simulation:
o Go to Simulate > Edit Simulation Cmd.
o Choose a Transient Analysis (e.g., for 10 seconds) to observe how
the circuit behaves over time.
o Click Run to start the simulation.

Components Summary
• 3 Voltage Sources for the 3S battery configuration (each at 4.15V).
• Resistor (0.001 ohm) for current sensing.
• MOSFET (N-channel) for high-current switching and protection.
• Comparator (Op-Amp) for overcurrent detection.
• Two Resistors for voltage divider (10k and 2k ohms).
• Current Source for charging.
 • Zener Diode for voltage limiting.
By following these steps, you’ll have a complete BMS circuit in LTspice that
meets the specific high-current tolerances, voltage monitoring, and charging
control. Let me know if you'd like further details on any part!

NETLIST

* 3S1P Battery Management System Circuit

* Voltage Sources for 3S1P Battery Pack

V1 N001 0 DC 4.15
V2 N002 N001 DC 4.15
V3 N003 N002 DC 4.15

* Shunt Resistor (Current Sensor)

R1 N003 N004 0.001

* MOSFET for Overcurrent Protection

M1 N002 N004 N005 N005 N_CHANNEL
.model N_CHANNEL NMOS (VTO=2 BETA=50 RS=0.01)

* Voltage Divider for Voltage Monitoring (Battery Voltage)

R2 N003 N006 10k
R3 N006 0 2k

* Comparator for Overcurrent Detection (Op-Amp Model)

XU1 N004 N005 N007 OPAMP_MODEL

* Current Source for Charging Simulation (Constant Current Mode)

I1 N003 0 DC 1A

* Zener Diode for Voltage Regulation (CV Mode)

D1 N003 0 D_MODEL

* Ground
GND 0 0

* Operating Temperature Setup

.model D_MODEL D(IS=10E-14 N=1.5 BV=12.5)
.model OPAMP_MODEL OPAMP(GBW=1Meg SlewRate=0.1Meg)
* Control Logic: Comparator and Gate Control
.subckt OPAMP_MODEL (IN+ IN- OUT)
Q1 1 0 NPN
Q2 2 0 PNP
R4 IN+ 1 1k
R5 IN- 2 1k
C1 OUT 1 10u
C2 OUT 2 10u
.model NPN NPN(IS=1E-14 BF=100)
.model PNP PNP(IS=1E-14 BF=100)
.ends

.tran 0.01 10
.end

Explanation of Key Components:

1. Battery Configuration (3S):
o V1, V2, and V3 represent the three series-connected battery cells,
each set to 4.15V.
o The total voltage across the pack is 12.45V (3 * 4.15V).
2. Current Sensor (Shunt Resistor):
o R1 is the shunt resistor for current sensing. The value is set to
0.001 ohms to detect high currents with minimal voltage drop.
3. Overcurrent Protection (MOSFET):
o M1 is an N-channel MOSFET connected between the battery and
the output to switch off when the current exceeds the specified
limits.
o The MOSFET has a threshold voltage VTO=2V, a BETA value for
current handling, and a small series resistance RS=0.01.
4. Voltage Divider (Voltage Monitoring):
o R2 and R3 form a voltage divider to scale the battery voltage down
to a safe level for monitoring.
o R2 is 10kΩ, and R3 is 2kΩ, so the voltage at node N006 is
approximately 1/6th of the battery voltage (scaled for easier
monitoring).
5. Comparator Circuit (Op-Amp Model):
 o XU1 is a comparator to detect the current flowing through the
shunt resistor and compare it with a reference voltage for
overcurrent protection.
o The comparator uses two transistors (Q1 and Q2) to create the
control logic for turning the MOSFET off if an overcurrent is
detected.
6. Current Source (Charging Simulation):
o I1 is a current source set to 1A for charging the battery. This
simulates a constant current charging mode.
7. Zener Diode for Voltage Regulation (CV Mode):
o D1 is a Zener diode that limits the voltage to 12.45V, ensuring the
battery doesn't exceed the safe charging voltage.
8. Grounding:
o GND is the ground reference for the circuit, and it's used as the
reference point for all other components.

How to Use the Netlist in LTspice:

1. Create a New Text File:
o Open Notepad or any text editor.
o Copy and paste the above netlist into the text editor.
o Save the file with a .cir extension (e.g., bms_circuit.cir).
2. Load the Netlist in LTspice:
o Open LTspice and go to File > Open.
o Select the .cir file you just created.
3. Run the Simulation:
o To simulate the behavior of the BMS, go to Simulate > Run.
o After running the simulation, you can observe the behavior of the
current, voltage, and the overcurrent protection logic in the
waveform viewer.

Important Notes:
1. Current Tolerance Protection:
o To implement the exact overcurrent protection thresholds (1000A
for 0.1s, 650A for 0.1s, etc.), you may need to modify the
comparator logic to trigger at different current levels and timing.
The simple current-sensing setup in the netlist will not account for
the exact time-based behavior of these protection levels, which
requires more advanced logic or a microcontroller-based
approach.
2. Simulation Time:
 oThe .tran command at the end sets up a transient analysis for 10
seconds with a time step of 0.01 seconds.
o You can adjust this based on the time constants you need to
simulate.
3. Temperature Effects:
o The operating temperature is simulated by setting the
temperature in the model settings. However, LTspice doesn't
handle real thermal modeling in detail, so you can simulate basic
temperature effects on the MOSFET or battery models by
adjusting their parameters (e.g., IS, BETA, and other temperature-
dependent properties).

This netlist represents a basic BMS circuit in LTspice for the specifications you
provided. For further detailed modeling, especially for complex temperature
and timing-based protection features, you may need to introduce more
advanced components or external control logic.

ERRORS
AFTER CORRECTING SOME ERRORS

* 3S1P Battery Management System Circuit

* Voltage Sources for 3S Battery Pack (3 series cells)

V1 N001 0 DC 4.15
V2 N002 N001 DC 4.15
V3 N003 N002 DC 4.15

* Shunt Resistor (Current Sensor)

R1 N003 N004 0.001

* MOSFET for Overcurrent Protection

M1 N002 N004 N005 N005 N_CHANNEL
.model N_CHANNEL NMOS (VTO=2 BETA=50 RS=0.01)

* Voltage Divider for Voltage Monitoring (Battery Voltage)

R2 N003 N006 10k
R3 N006 0 2k

* Current Source for Charging Simulation (Constant Current Mode)

I1 N003 0 DC 1A

* Zener Diode for Voltage Regulation (CV Mode)

D1 N003 0 D_MODEL
* Comparator for Overcurrent Detection (Op-Amp Model)
XU1 N004 N005 N007 OPAMP_MODEL

* NPN and PNP Transistor Models for Comparator

.model NPN NPN(IS=1E-14 BF=100)
.model PNP PNP(IS=1E-14 BF=100)

* Zener Diode Model

.model D_MODEL D(IS=1E-14 N=1.0 BV=4.7 IBV=0.1)

* Control Logic: Comparator and Gate Control

.subckt OPAMP_MODEL (IN+ IN- OUT)
Q1 IN+ N003 N001 NPN
Q2 IN- N002 N001 PNP
R4 IN+ N003 1k
R5 IN- N002 1k
C1 OUT N003 10u
C2 OUT N001 10u
.ends

* Ground node (0) definition, ensuring all paths are connected

GND 0 0

* Simulation Settings
.tran 0.01 10
.end