Battery Management System for EVs and Battery Packs

Dr. Vinod H. Patil

Bharati Vidyapeeth (Deemed to be University) College of Engineering, Pune (India)

Abstract:

The battery management system (BMS) is a crucial system component in many applications, including
telecommunications, UPS, electric cars (EV), hybrid electric vehicles (HEV), and others. The accuracy
of these methods has always been a contentious issue because, when all the criteria are considered,
they frequently result in an error of about 10%. Many industrial and commercial systems use battery
management systems (BMS) to enhance battery performance and predict how long a battery should
be in a non-destructive state to increase battery life. This is accomplished by monitoring the battery's
temperature, current, and charge states using several monitoring techniques. In the current study,
the battery-powered Electric Vehicle (EV) monitoring system has been installed and evaluated. This
system evaluates and displays for the model battery under consideration the battery temperature,
charging and discharging current, and State of Charge (SOC). For monitoring, digital, and analogue
sensors, as well as microcontrollers, are used. The LCD panel shows some of the testing data, and
photographs are utilised to convey the battery information and the results that describe the system's
major capabilities. To maintain track of all the crucial battery parameters, a system that was
developed utilising mathematical principles is shown in this project.

Keywords: Li-Ion battery, Energy Storage Systems (ESS), State of Charge (SOC), Battery Model,
Battery Management System

I. INTRODUCTION

In recent years, the development of EV and HEV technologies has quickened. Commonly
acknowledged as the most promising alternatives to conventional internal combustion (IC) engine-
based vehicles are electric vehicles (EVs) and hybrid electric vehicles (HEVs). Batteries are widely
employed as the power source for EVs and HEVs due to its advantages including high energy density,
low environmental pollution, and long cycle life. Batteries must, however, be managed carefully when
used in EV applications. As a result of incorrect operations like over-current, over-voltage, or over-
charging/discharging, the batteries will encounter major safety problems. These inappropriate
activities will also speed up ageing significantly and might even cause a fire or explosion. The battery
management system (BMS) is therefore crucial for ensuring the efficiency and security of batteries.
Technologies that are crucial to EV BMS include battery modelling, internal state estimations, and
battery charging.

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An effective battery model is crucial for battery behaviour analysis, battery state monitoring, real-time
controller design, temperature management, and fault diagnosis. Additionally, since a few internal
battery conditions, including state of charge (SOC), state of health (SOH), and internal temperature,
cannot be directly detected yet are necessary for monitoring a battery's operation, they must be
monitored using precise estimating approaches. Furthermore, battery charging is essential to BMS
since it has an immediate impact on the battery's use for servicing and operational security. A well-
thought-out charging schedule is utilised to prevent battery degeneration, manage temperature
fluctuations, and improve energy efficiency.

II. LITERATURE SURVEY

This article evaluates key BMS technologies for EVs, focusing on the areas of battery modelling, state
estimation, and battery charging. Battery modelling and estimations of the battery's internal states
and attributes are essential for revealing a hologram of the operating status of the battery in EV
applications. A proper battery charging strategy can be developed to safeguard the battery, increase
energy conversion efficiency, and extend battery lifetime. The great majority of the BMS's basic
technologies, however, are developed and evaluated test environments.

It is challenging to ensure the modelling, estimating, and charging performance in real-world

applications that could differ from the test settings or in the worst-case scenario. It was developed
and put through testing as a modular battery management system. This BMS delivers noteworthy
advantages in the core areas of voltage measuring, accumulated charge measurement, and
equalisation. To reduce expenses, a very precise circuit that provides up to 12 readings per module is
utilised to monitor voltage. A counter and a precision V/F converter are used by the charge
measurement circuit to integrate the current waveform. The outcome is an increase in the time before
the measurement needs to be reset.

Equalization is accomplished using a very straightforward current routing circuit that increases the
charge on low voltage part, as opposed to the more common method of discharging higher voltage
segments. A 48 cell Li-Ion battery pack has been used for rigorous testing and verification of every
function. Surface mount technology is employed throughout to save costs, volume, and mass.
Comparing the two systems, the modular system is 70% and 87% lighter as well as 75% smaller in
volume. This study introduces the basic operations and overall structure of the lithium-ion BMS. Three
3400MAH lithium cobalt oxide batteries connected in series are also given a BMS experimental
platform.

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The experimental platform is capable of accurately detecting voltage and current, computing SOC,
controlling balance, and other activities. It is explained in detail how to combine the SOC estimate
using the current integration method and the open-circuit voltage methodology. The testing results
show that this combination method has a cumulative error of 1.1 percent following the completion of
the 80-minute charging process, and the calculating error can be reduced. In this work, we proposed
a BMS algorithm that considers battery efficiency. The algorithm was implemented on an ESS to
improve the battery's safety and performance. In this work, we proposed a BMS algorithm that
considers battery efficiency. The technique was used to enhance the performance and security of a
battery using an ESS.

The algorithm was divided into three parts for this investigation. First, the battery's efficiency was
used to determine its condition. The difference between charging and discharging power was used to
evaluate the internal resistance of the battery to calculate the value of the variable internal resistance.
The variation in internal resistance was corroborated by the experimental results, which showed a rise
in the charging-discharging power difference during battery operation.

After that, the SoC and SoH estimate techniques were presented. the method of combining SoC
estimate with OCV and CCM. The method of merging OCV and CCM with estimated battery states was
devised for SoC estimation to accommodate for both low initial CCM estimation accuracy and
imprecise OCV estimation. Scientists, engineers, and researchers are paying more attention to this
field of study. RUL prediction strategies and method comparisons with more than 150 study reviews:
Given the importance of RUL prediction for battery and other systems, various RUL prediction
approaches as well as prospective future research avenues were evaluated.

III. RESEARCH OBJECTIVES

The objectives of the project are described as follows: By utilising easily accessible dedicated
integrated circuits and microcontrollers, a new BMS platform with a focus on quick sampling, high
accuracy, low consumption, and low cost can be created. To facilitate the creation of multiple charging
and balancing algorithms, we built an open system that can be used with many different battery
models. On an ISR, we set up a functional prototype, and we reworked the required experimental
tests to confirm the idea. We used the ISR-BMS as a baseline and contrasted it with the current crop
of commercial BMSs.

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 IV. BLOCK DIAGRAM

One battery pack with three 1.5V per cells was used in this instance. Our system measured the
following setup parameters: Voltage, measured using the PIC microcontroller's ADC port;
Temperature, measured using an LM35 sensor; Current, measured using an ACS712 sensor. All these
measurements were then presented on the display unit's LCD panel. Finally, a voltage safety circuit is
connected to guard against accidents and shield the circuit from damage in the event of a surge by
grounding it.

V. PROBLEM STATEMENT AND SCOPE

Many times, tractor-trailer drivers are forced to spend the night in their trucks due to a lack of lodging
options, a desire to save money, or just because it is more practical. Because the drivers often need
to utilise the heating and cooling systems in the cabin and don't want to empty the battery overnight,
the truck's engine is regularly left on at night, idling the entire time. Due to the fuel consumption and
engine attrition, this is not the wisest course of action. Cummins, Inc. is therefore considering
developing a "hotel system of charging" to incorporate into an engine package. A battery management
system, which would be used in this system, would govern the engine's periodic activation to recharge
the battery when it starts to lose charge or if the environment becomes too hot to use the battery.
Truckers can use the truck battery to power their systems safely at night using this technique, knowing
that the engine will start when necessary to recharge the battery before turning off once more.

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VI. SIMULATION AND RESULTS
A) Output Voltage

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B) Current and Temperature

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C) SOC Reading

Parameter Values(measured)

Voltage 0-4.149V

Current 12mA

Temperature 100-600C

SOC 72%

Table 1: Output Values

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VII. CONCLUSION

The BMS uses a single microcontroller to manage the battery cells. A prototype system consisting
of three series-connected 3.6 Ah Li-ion battery cells is shown, along with the experimental results
for this system. On an LCD, information regarding the voltage and current of the battery cells was
displayed. On the LCD, both the temperature and SoC were concurrently displayed. A protection
circuit has also been added to protect the battery cells. In this study, we proposed a BMS algorithm
that considers battery efficiency. The algorithm was implemented on an ESS to improve the
battery's safety and performance. The efficiency of the battery served as a gauge for its state of
health. The difference between charging and discharging power was used to evaluate the internal
resistance of the battery to calculate the value of the variable internal resistance. The variation in
internal resistance was corroborated by the experimental results, which showed a rise in the
charging-discharging power difference during battery operation.

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