BATTERY MANAGEMENT SYSTEM

Submitted By: Shivin Shyam Kasat

 TABLE OF CONTENTS

1. Battery Management System

1.1What is Battery Management System ?
1.2. How do battery management systems work?

1.2.1. Electrical Management Protection: Current

1.2.2. Electrical Management Protection: Voltage

1.2.3. Thermal Management Protection: Temperature

1.3. Capacity Management

1.4. The importance of battery management systems

1.5. The benefits of battery management systems

1.6. Existing Solutions for Battery Management Systems (BMS)

2. Software Required

2.1. Introduction

2.2. PCB Design Software

2.2.1. Simulation and Circuit Analysis Software

2.2.2. Embedded Development and Firmware Programming

2.2.3. Battery Simulation and Management Software

2.2.4. Battery Modeling and Data Analysis

2.2.5. Monitoring and Diagnostic Tools

2.2.6. Thermal and Mechanical Design Software

2.2.7. Energy Management Software

2.2.8. Open-Source and Custom BMS Software

2.3 Software used

2.4. Key Features of the Arduino IDE

 2.5. Why do we use Arduino IDE in BMS

2.6. Conclusion

3. Hardware Requirements

3.1. Battery Management System (BMS)

3.1. Circuit diagram overview

4. PCB Connections & Code

4.1. Code

4.2. Block Diagram

5. Result & Conclusion

5.1. Result

5.2. Conclusion
 CHAPTER 1: Battery management system

1.1 What is Battery Management System ?

A battery management system (BMS) is an electronic structure that controls the charging and discharging

of the battery, is responsible for the safety of its operation, monitors the state of the battery, and evaluates

secondary performance data The BMS provides individual control of the voltage and resistance of each

cell, determines the loss of capacity due to imbalance, and ensures safe connection/disconnection of the

load. The functionality of BMS improves the operating mode and service life of EV batteries. The BMS

monitors and regulates the safety circuitry of the electric vehicle. When problematic conditions such as

overvoltage or overheating are detected, the BMS alerts the user and initiates the predetermined corrective

procedure. In addition to these activities, the BMS monitors electric vehicle temperature to optimize energy

use and communicates with specific components and operators. Without a BMS, an electric vehicle's energy

management will be unpredictable, leaving it vulnerable to various safety hazards that could result in

catastrophic failures such as a short circuit or thermal meltdown of the battery. Therefore, the BMS is vital

for an electric vehicle's safety and efficient power management.

A Battery Management System (BMS) is an essential component in modern rechargeable battery-powered

applications such as electric vehicles (EVs), renewable energy systems, and portable electronics. Its primary

purpose is to monitor, manage, and safeguard battery performance, ensuring that the battery operates

efficiently and safely throughout its lifecycle.

It is a technology dedicated to the oversight of a battery pack, which is an assembly of battery cells,

electrically organized in a row x column matrix configuration to enable delivery of targeted range of voltage

and current for a duration of time against expected load scenarios.

The BMS performs various critical functions, including:

 • Monitoring: The BMS continuously tracks battery parameters such as voltage, current,

temperature, and state of charge (SOC).

• Protection: It prevents the battery from operating outside its safe limits, protecting against

overcharging, over-discharging, over-temperature, and short circuits.

• Balancing: In multi-cell batteries, BMS ensures that individual cells within the battery pack remain

balanced to prevent over-stressing any particular cell.

• State Estimation: The BMS estimates important metrics like the remaining capacity, state of health

(SOH), and state of energy (SOE) to give accurate readings on the battery's status.

1.2. How do battery management systems work?

Battery management systems do not have a fixed or unique set of criteria that must be adopted. The

technology design scope and implemented features generally correlate with:

• The costs, complexity, and size of the battery pack

• Application of the battery and any safety, lifespan, and warranty concerns

• Certification requirements from various government regulations where costs and penalties are

paramount if inadequate functional safety measures are in place

There are many BMS design features, with battery pack protection management and capacity management

being two essential features. We’ll discuss how these two features work here. Battery pack protection

management has two key arenas: electrical protection, which implies not allowing the battery to be damaged

via usage outside its SOA, and thermal protection, which involves passive and/or active temperature control

to maintain or bring the pack into its SOA.

1.2.1. Electrical Management Protection: Current

Monitoring battery pack current and cell or module voltages is the road to electrical protection. The

electrical SOA of any battery cell is bound by current and voltage. Lithium-ion cells have different current

limits for charging than for discharging, and both modes can handle higher peak currents, albeit for short

time periods. Battery cell manufacturers usually specify maximum continuous charging and discharging

current limits, along with peak charging and discharging current limits. A BMS providing current protection

will certainly apply a maximum continuous current. However, this may be preceded to account for a sudden

change of load conditions; for example, an electric vehicle’s abrupt acceleration. A BMS may incorporate

peak current monitoring by integrating the current and after delta time, deciding to either reduce the

available current or to interrupt the pack current altogether. This allows the BMS to possess nearly

instantaneous sensitivity to extreme current peaks, such as a short-circuit condition that has not caught the

attention of any resident fuses, but also be forgiving to high peak demands, as long as they are not excessive

for too long.

1.2.2. Electrical Management Protection: Voltage

Moreover, since any battery pack experiences a significant amount of current cycling, discharging due to

load demands and charging from a variety of energy sources, these SOA voltage limits are usually further

constrained to optimize battery lifespan. The BMS must know what these limits are and will command

decisions based upon the proximity to these thresholds. For example, when approaching the high voltage

limit, a BMS may request a gradual reduction of charging current, or may request the charging current be

terminated altogether if the limit is reached. However, this limit is usually accompanied by additional

intrinsic voltage hysteresis considerations to prevent control chatter about the shutdown threshold. On the

other hand, when approaching the low voltage limit, a BMS will request that key active offending loads

reduce their current demands. In the case of an electric vehicle, this may be carried out by reducing the
allowed torque available to the traction motor. Of course, the BMS must make safety considerations for the

driver the highest priority while protecting the battery pack to prevent permanent damage.

1.2.3. Thermal Management Protection: Temperature

At face value, it may appear that lithium-ion cells have a wide temperature operating range, but overall

battery capacity diminishes at low temperatures because chemical reaction rates slow down remarkably.

With respect to capability at low temperatures, they do perform much better than lead-acid or NiMh

batteries; however, temperature management is prudently essential since charging below 0 °C (32 °F) is

physically problematic. The phenomenon of plating of metallic lithium can occur on the anode during sub-

freezing charging. This is permanent damage and not only results in reduced capacity, but cells are more

vulnerable to failure if subjected to vibration or other stressful conditions. A BMS can control the

temperature of the battery pack through heating and cooling.

1.3. Capacity Management

Maximizing a battery pack capacity is arguably one of the most vital battery performance features that a

BMS provides. If this maintenance is not performed, a battery pack may eventually render itself useless.

The root of the issue is that a battery pack “stack” (series array of cells) is not perfectly equal and

intrinsically has slightly different leakage or self-discharge rates. Leakage is not a manufacturer defect but

a battery chemistry characteristic, though it may be statistically impacted from minute manufacturing

process variations. Initially a battery pack may have well-matched cells, but over time, the cell-to-cell

similarity further degrades, not just due to self-discharge, but also impacted from charge/discharge cycling,

elevated temperature, and general calendar aging. With that understood, recall earlier the discussion that

lithium-ion cells perform superbly, but can be rather unforgiving if operated outside a tight SOA. We learned

previously about required electrical protection because lithium-ion cells do not deal well with over-

charging. Once fully charged, they cannot accept any more current, and any additional energy pushed into

it gets transmuted in heat, with voltage potentially rising quickly, possibly to dangerous levels. It is not a

healthy situation for the cell and can cause permanent damage and unsafe operating conditions if it

continues.
The battery pack series cell array is what determines the overall pack voltage, and mismatch between

adjacent cells creates a dilemma when attempting to charge up any stack. Figure 3 shows why this is so. If

one has a perfectly balanced set of cells, all is fine as each will charge up in equal fashion, and the charging

current can be cut off when the upper 4.0 voltage cut-off threshold is reached. However, in the unbalanced

scenario, the top cell will reach its charge limit early, and the charging current needs to be terminated for

the leg before other underlying cells have been charged to full capacity.

1.4. The importance of battery management systems

Functional safety is of the highest importance in a BMS. It is critical during charging and discharging

operation, to prevent the voltage, current, and temperature of any cell or module under supervisory control

from exceeding defined SOA limits. If limits are exceeded for a length of time, not only is a potentially

expensive battery pack compromised, but dangerous thermal runaway conditions could ensue. Moreover,

lower voltage threshold limits are also rigorously monitored for the protection of the lithium-ion cells and

functional safety. If the Li-ion battery stays in this low-voltage state, copper dendrites could eventually
grow on the anode, which can result in elevated self-discharge rates and raise possible safety concerns. The

high energy density of lithium-ion powered systems comes at a price that leaves little room for battery

management error. Thanks to BMSs, and lithium-ion improvements, this is one of the most successful and

safe battery chemistries available today.

Performance of the battery pack is the next highest important feature of a BMS, and this involves electrical

and thermal management. To electrically optimize the overall battery capacity, all the cells in the pack are

required to be balanced, which implies that the SOC of adjacent cells throughout the assembly are

approximately equivalent. This is exceptionally important because not only can optimal battery capacity be

realized, but it helps prevent general degradation and reduces potential hotspots from overcharging weak

cells. Lithium-ion batteries should avoid discharge below low voltage limits, as this can result in memory

effects and significant capacity loss. Electrochemical processes are highly susceptible to temperature, and

batteries are no exception. When environmental temperature drops, capacity and available battery energy

roll off significantly. Consequently, a BMS may engage an external in-line heater that resides on, say, the

liquid cooling system of an electric vehicle battery pack, or turn-on resident heater plates that are installed

underneath modules of a pack incorporated within a helicopter or other aircraft. Additionally, since charging

of frigid lithium-ion cells is detrimental to battery life performance, it is important to first elevate the battery

temperature sufficiently. Most lithium-ion cells cannot be fast-charged when they are less than 5°C and

should not be charged at all when they are below 0°C. For optimum performance during typical operational

usage, BMS thermal management often ensures that a battery operates within a narrow Goldilocks region

of operation (e.g. 30 – 35°C). This safeguards performance, promotes longer life, and fosters a healthy,

reliable battery pack.

1.5. The benefits of battery management systems

An entire battery energy storage system, often referred to as BESS, could be made up of tens, hundreds, or

even thousands of lithium-ion cells strategically packed together, depending on the application. These

systems may have a voltage rating of less than 100V, but could be as high as 800V, with pack supply currents
ranging as high as 300A or more. Any mismanagement of a high voltage pack could trigger a life-

threatening, catastrophic disaster. Consequently, therefore BMSs are absolutely critical to ensure safe

operation. The benefits of BMSs can be summarized as follows.

• Functional Safety. Hands down, for large format lithium-ion battery packs, this is particularly

prudent and essential. But even smaller formats used in, say, laptops, have been known to catch fire

and cause enormous damage. Personal safety of users of products that incorporate lithium-ion

powered systems leaves little room for battery management error.

• Life Span and Reliability. Battery pack protection management, electrical and thermal, ensures

that all the cells are all used within declared SOA requirements. This delicate oversight ensures the

cells are taken care of against aggressive usage and fast charging and discharging cycling, and

inevitably results in a stable system that will potentially provide many years of reliable service.

• Performance and Range. BMS battery pack capacity management, where cell-to-cell balancing

is employed to equalize the SOC of adjacent cells across the pack assembly, allows optimum battery

capacity to be realized. Without this BMS feature to account for variations in self-discharge,

charge/discharge cycling, temperature effects, and general aging, a battery pack could eventually

render itself useless.

• Diagnostics, Data Collection, and External Communication. Oversight tasks include

continuous monitoring of all battery cells, where data logging can be used by itself for diagnostics,

but is often purposed to the task for computation to estimate the SOC of all cells in the assembly.

This information is leveraged for balancing algorithms, but collectively can be relayed to external

devices and displays to indicate the resident energy available, estimate expected range or

range/lifetime based on current usage, and provide the state of health of the battery pack.

• Cost and Warranty Reduction. The introduction of a BMS into a BESS adds costs, and battery

packs are expensive and potentially hazardous. The more complicated the system, the higher the
 safety requirements, resulting in the need for more BMS oversight presence. But the protection and

preventive maintenance of a BMS regarding functional safety, lifespan and reliability, performance

and range, diagnostics, etc. guarantees that it will drive down overall costs, including those related

to the warranty.

• Optimized Charging: A BMS manages the charging process to prevent overcharging and

overheating. By regulating the charging current and voltage, the BMS ensures efficient charging

while minimizing stress on the battery cells. Some BMS systems also offer fast-charging

capabilities, further enhancing the usability of the battery system.

• Cell Balancing: In large battery packs, individual cells may exhibit slight variations in capacity

and voltage due to manufacturing tolerances or aging effects. The BMS performs cell balancing,

either through passive or active methods, to equalize the charge levels of each cell, ensuring that

no cell is overstressed during operation.

• Remote Monitoring and Control: With advances in Internet of Things (IoT) technology, some

BMS solutions now offer remote monitoring and control capabilities. This allows operators to

monitor the status of battery systems in real-time from remote locations, enhancing convenience

and enabling proactive maintenance.

1.5. Disadvantages of Battery Management Systems

• Increased Cost: Adding a BMS to a battery system increases its overall cost. This is particularly

evident in large-scale applications like EVs or renewable energy storage, where the BMS needs to

be highly sophisticated to manage hundreds or thousands of cells. For smaller applications, the cost

of the BMS can be a significant portion of the total system cost.

• Complexity: The design and implementation of a BMS are complex, requiring intricate hardware

and software. The system must be tailored to the specific battery chemistry, configuration, and
 application, which increases the design and development effort. Additionally, the more advanced

features, such as wireless monitoring or active balancing, further add to the system's complexity.

• Energy Consumption: The BMS itself consumes power, which can slightly reduce the overall

efficiency of the battery system. Although the power consumption of a BMS is relatively low, it

can still be a concern in applications where maximizing battery efficiency is critical, such as in

portable devices or electric vehicles.

• Maintenance and Calibration: While BMS systems are designed to be reliable, they still require

regular maintenance and calibration to ensure accurate measurements and proper functioning.

Calibration is especially important for systems that rely on precise SOC or SOH estimations. Over

time, sensor drift or software bugs can lead to inaccurate data, necessitating periodic recalibration.

• Failure Risks: Although BMSs are designed to improve safety and reliability, they are not immune

to failure. If the BMS malfunctions or provides incorrect data, it could lead to improper battery

management, potentially causing damage to the battery or posing safety risks. For example, if the

BMS fails to detect an overvoltage condition, the battery could overheat, resulting in a fire.

1.6. Existing Solutions for Battery Management Systems (BMS)

Battery Management Systems (BMS) come in various forms and configurations, depending on the

application and the complexity of the battery system they are managing. Below are the most

common existing solutions for BMS, each tailored to different requirements, scales, and levels of

sophistication:

1. Standalone Battery Management Systems

Overview: Standalone BMS units are designed for small-scale applications such as consumer

electronics, portable power tools, and other low-power devices. These systems are typically pre-

configured and self-contained, providing basic battery protection and monitoring functions.

Key Features:
• Basic protection against overcharging, over-discharging, and short circuits.

• Simple monitoring of voltage and current, with SOC and SOH estimation.

• Often integrated with the battery pack and not designed for extensive external control or

monitoring.

Applications:

• Smartphones

• Laptops

• Power tools

• Consumer electronics

Advantages:

• Low cost and easy integration into small devices.

• Compact design, optimized for space and weight efficiency.

Disadvantages:

• Limited functionality, particularly in terms of cell balancing and scalability.

• Inadequate for larger systems with multiple cells or higher power requirements.

2. Modular Battery Management Systems

Overview: Modular BMS solutions are designed for medium- to large-scale applications, such as

electric vehicles (EVs) and large energy storage systems. They are composed of individual modules,

each with its own BMS, which communicate with a central controller. These modular systems allow

for scalability and redundancy, making them well-suited for applications that require higher capacity

and safety.

Key Features:

• Multiple modules, each with its own monitoring and control capabilities.

• Centralized communication and control, often using a master-slave architecture.

• Modular design allows for easy expansion to accommodate more cells.

 Applications:

• Electric vehicles (EVs)

• Hybrid electric vehicles (HEVs)

• Renewable energy storage systems (e.g., solar or wind farms)

• Industrial battery applications

Advantages:

• Scalable to accommodate large battery packs with hundreds or thousands of cells.

• Redundancy enhances system reliability; individual module failures don't necessarily lead to total

system failure.

• Supports advanced features like cell balancing, temperature monitoring, and fault detection.

Disadvantages:

• More complex and expensive than standalone systems.

• Requires coordination between modules and a central controller, which can add design challenges.

3. Distributed Battery Management Systems

Overview: Distributed BMS solutions are an advanced type of system, particularly suited for high-

performance or high-reliability applications. Instead of having a centralized controller, each battery

cell (or group of cells) has its own individual BMS, which communicates with other cells to manage

the overall battery pack. This decentralized approach allows for extremely precise control over

individual cells and offers superior fault tolerance.

Key Features:

• Each cell or small group of cells has its own dedicated BMS.

• Communication between BMS units allows for system-wide coordination.

• Highly redundant and fault-tolerant design.

Applications:

• High-performance electric vehicles (e.g., race cars, aircraft)

• Aerospace applications

• Industrial-grade energy storage

• Critical infrastructure power systems

Advantages:

• Superior control over individual cells, leading to higher reliability and efficiency.

• Faults in one cell or unit are isolated, preventing them from affecting the entire system.

• Flexibility in managing large and complex battery arrays.

Disadvantages:

• High complexity and cost, both in terms of hardware and software.

• Requires sophisticated communication protocols to coordinate the distributed systems.

4. Integrated Battery Management Systems

Overview: Integrated BMS solutions combine the BMS functionality with other electronic systems,

such as motor controllers, DC-DC converters, or power management systems. This integrated

approach reduces the overall system complexity and weight, making it ideal for applications where

space is limited or where higher levels of efficiency are required.

Key Features:

• Combines BMS with other power electronics in a single unit.

• Optimized for space and weight, often used in compact applications.

• Typically offers high efficiency due to reduced energy losses between components.

Applications:

• Electric scooters, bicycles, and small EVs

• Drones and unmanned aerial vehicles (UAVs)

• Portable power stations

Advantages:

• Reduces overall system complexity and component count, saving space and weight.
• Improved system efficiency due to integrated power management.

• Easier to implement in compact or mobile systems.

Disadvantages:

• Limited scalability and customization compared to modular or distributed systems.

• If the integrated unit fails, multiple systems (BMS, motor controller, etc.) could be affected.

5. Cloud-Connected Battery Management Systems (IoT-Enabled)

Overview: With the advancement of IoT technology, some BMS solutions are now cloud-

connected, allowing remote monitoring, control, and data analysis. Cloud-connected BMS solutions

provide real-time data on battery performance and health, enabling predictive maintenance, system

optimization, and more efficient fleet or infrastructure management.

Key Features:

• Real-time data monitoring and logging through cloud platforms.

• Remote control and diagnostics of battery systems.

• Predictive maintenance and fleet management capabilities.

Applications:

• Electric vehicle fleets (EVs, buses, delivery trucks)

• Grid-scale energy storage systems

• Renewable energy systems (solar, wind)

• Smart homes and smart grids

Advantages:

• Remote monitoring and control, reducing the need for on-site maintenance.

• Predictive analytics to prevent failures and extend battery life.

• Data-driven optimization of battery usage and charging.

Disadvantages:

• High implementation costs, including infrastructure for cloud connectivity.

• Potential cybersecurity risks related to data transmission and remote control.

• Requires reliable internet access for continuous monitoring.

6. Active and Passive Cell Balancing Battery Management Systems

Overview: Cell balancing is an essential feature in multi-cell battery packs to ensure that each cell

operates within optimal voltage limits. BMS solutions can employ either passive or active balancing

techniques. Passive balancing dissipates excess energy from high-voltage cells as heat, while active

balancing redistributes energy between cells more efficiently.

Key Features:

• Passive Balancing: Dissipates excess energy as heat; simpler and less expensive.

• Active Balancing: Transfers energy between cells; more complex but reduces energy loss.

Applications:

• Electric vehicles (EVs) and hybrid electric vehicles (HEVs)

• Large-scale energy storage systems

• Industrial battery packs

Advantages:

• Passive Balancing: Simple, low-cost, effective for basic balancing needs.

• Active Balancing: Reduces energy loss, improves efficiency, and prolongs battery life.

Disadvantages:

• Passive Balancing: Energy wasted as heat; less efficient.

• Active Balancing: More complex and expensive; requires additional electronics and control

systems.
 Chapter 2: Software Required

2.1. Introduction

There are various software tools used for the design, simulation, development, and management of

Battery Management Systems (BMS). These software platforms range from hardware design tools

(PCB design, circuit simulation) to embedded development environments for programming

microcontrollers and advanced battery management solutions. Below is an overview of different

software categories and examples used in BMS development:

2.2. PCB Design Software

PCB design software is essential for laying out the physical design of the BMS and managing power

and signal traces effectively.

• KiCad: Open-source PCB design tool used for creating schematics and designing PCB layouts. It’s

popular for custom BMS designs.

• EAGLE: A professional PCB design tool used for circuit design, simulation, and PCB layout.

Many custom BMS projects are designed with EAGLE due to its ease of use and integration with

online component libraries.

• Altium Designer: High-end PCB design software for professional BMS development, offering

advanced simulation and multi-layer PCB design capabilities.

• EasyEDA: A web-based PCB design tool with both schematic capture and PCB layout capabilities.

It’s ideal for quick and simple BMS designs.

2.2.1. Simulation and Circuit Analysis Software

Simulation tools allow engineers to test circuits and components in a virtual environment before

committing to hardware designs.

• LTspice: A powerful, free SPICE-based simulator widely used for simulating circuits, including

those for battery management (e.g., balancing circuits, protection circuits).

• Proteus: A simulation platform that integrates both circuit design and microcontroller simulation.

It allows you to simulate an entire BMS circuit along with an Arduino or other microcontrollers.

• PSpice: An industry-standard SPICE simulator used for analog and mixed-signal simulation. It is

useful for modeling complex battery systems and protection circuits in BMS.

2.2.2. Embedded Development and Firmware Programming

Microcontrollers like Arduino, ESP32, and STM32 are commonly used in BMS for control and

monitoring. Software for embedded development includes:

• Arduino IDE: The Integrated Development Environment (IDE) used to program Arduino

microcontrollers. It is often used in DIY or custom BMS solutions.

• PlatformIO: A modern, cross-platform IDE that supports embedded systems development with

Arduino, ESP32, STM32, and many other microcontrollers. It’s highly extensible and popular for

larger projects.

• STM32CubeIDE: For projects using STM32 microcontrollers, this IDE supports advanced

features like real-time data monitoring and low-power management for BMS.

2.2.3. Battery Simulation and Management Software

For advanced BMS applications like electric vehicles (EVs) and grid-scale energy storage,

specialized battery management and simulation software is used to predict performance, optimize

efficiency, and ensure safety.

• Simulink (with MATLAB): A popular tool for designing and simulating battery management

systems, particularly for electric vehicles. Simulink provides blocks for simulating battery

behavior, control systems, and communication protocols.

• Battery Design Studio: Used for battery cell and system design, this software can model and

simulate battery packs for BMS development. It helps engineers evaluate battery performance and

optimize designs.
• AVL CRUISE™: A simulation tool used for designing and validating battery electric and hybrid

electric vehicles. It’s helpful in assessing energy flow, BMS algorithms, and overall system

performance.

2.2.4. Battery Modeling and Data Analysis

In complex BMS projects, real-world data is crucial to model battery performance, predict

degradation, and improve system management.

• ANSYS Battery Design Module: Offers modeling for electrochemical cells, thermal management,

and mechanical behavior of battery systems. It’s useful for creating realistic simulations of BMS

and battery systems under different conditions.

• Autonomie: A simulation software developed by Argonne National Laboratory to optimize vehicle

powertrains, including BMS. It models various battery chemistries and control systems.

• Battery State of Health (SoH) Estimation Software: Many research-based and custom tools help

track battery state of health (SoH), capacity, and other key metrics.

2.2.5. Monitoring and Diagnostic Tools

Monitoring tools are essential for real-time analysis, debugging, and diagnostics of BMS systems

during operation.

• Battery Management System GUI: Some BMS modules come with dedicated graphical user

interfaces (GUIs) for real-time monitoring and control. These interfaces often support

communication protocols like CAN bus, I2C, or UART to display data such as cell voltages,

temperatures, and state of charge (SoC).

• CANalyzer: A software tool from Vector for analyzing and testing communication in systems

using the CAN protocol. It's helpful in debugging and optimizing BMS communication in electric

vehicles and other large battery systems.

2.2.6. Thermal and Mechanical Design Software

Thermal management is critical in BMS design to prevent overheating and improve longevity.
• COMSOL Multiphysics: Used for modeling thermal and mechanical effects in battery systems, it

provides insights into heat generation and distribution in battery packs, aiding in the design of

cooling systems for BMS.

• SolidWorks: A mechanical CAD software that allows engineers to design enclosures, cooling

systems, and battery pack layouts. It can be used in conjunction with thermal simulation tools to

design the physical aspects of the BMS.

2.2.7. Energy Management Software

For large-scale battery management systems, especially in renewable energy storage and smart

grids, energy management software integrates BMS with the broader energy infrastructure.

• Homer Pro: Used for optimizing energy storage systems, including batteries in microgrids or

hybrid systems. It integrates the BMS into the overall energy management plan.

• Grid-BMS: Software specifically designed for grid-connected battery energy storage systems. It

ensures that battery systems work optimally with the grid, balancing charge/discharge cycles and

protecting battery longevity.

2.2.8. Open-Source and Custom BMS Software

Some developers use open-source BMS software to create custom battery management solutions.

• SimpleBMS: An open-source software platform for DIY BMS solutions. It’s commonly used in

projects involving Arduino and other microcontrollers for basic battery monitoring and protection.

• OpenBMS: An open-source platform that provides resources and tools to develop and customize

battery management systems, typically for educational purposes or hobbyist projects.

2.3. Software Used

The Arduino Integrated Development Environment (IDE) is the official software platform used

to write, compile, and upload code to Arduino microcontrollers. It is an easy-to-use environment

tailored for beginners and hobbyists, but also powerful enough for advanced users and professionals.
 The IDE supports various Arduino boards, such as Arduino Uno, Nano, Mega, and others. Below is

a detailed overview of the Arduino IDE, its features, and how to use it.

2.4. Key Features of the Arduino IDE

2.4.1. Code Editor

• Syntax Highlighting: The IDE highlights different elements of code, such as keywords, functions,

variables, and constants, in different colors for readability.

• Auto-indentation: Automatically formats code for better organization and readability.

• Line Numbering: Provides easy reference to specific parts of the code.

• Bracket Matching: Automatically highlights matching brackets and parentheses to reduce syntax

errors.

2.4.2. Sketch System

• Sketch: A program written for Arduino is called a "sketch." All sketches are saved with the .ino

extension (e.g., [Link]).

• Code Structure: Each sketch has two main functions:

o setup(): Runs once when the board is powered or reset. This is where initialization (like pin mode

configuration) occurs.

o loop(): Contains the main code that runs repeatedly after setup().

2.4.3. Libraries

• Built-in Libraries: The IDE includes libraries for commonly used tasks (e.g., controlling motors,

handling sensors, or communicating via protocols like I2C or SPI).

• External Libraries: You can add custom libraries from external sources to extend the functionality

of the Arduino (e.g., controlling OLED displays, sensors, etc.).

• Library Manager: This feature allows you to search, install, update, and manage libraries directly

from the IDE.

2.4.5. Compilation and Uploading

• Verify/Compile: The IDE checks your code for syntax errors and compiles it into machine code

that can be uploaded to the Arduino board.

• Upload: After compiling, the IDE uploads the code to the connected Arduino via a USB port. This

process converts the code into a format the Arduino’s microcontroller can execute.

2.4.6. Serial Monitor and Plotter

• Serial Monitor: Allows real-time communication with the Arduino. You can send and receive data

over a serial connection, which is useful for debugging and monitoring sensor data.

• Serial Plotter: Plots real-time sensor data in graphical form, making it easier to visualize data

trends over time.

2.4.7. Board and Port Selection

• Board Manager: The IDE supports a wide range of Arduino-compatible boards. The Board

Manager lets you install and manage support packages for official and third-party boards.

• Port Selection: You can select the communication port to which the Arduino is connected, ensuring

the correct board is targeted for code uploads.

2.4.8. Debugging

• Basic Debugging: The IDE itself has no built-in debugging tools (like breakpoints), but debugging

can be done using the Serial Monitor by printing variables and monitoring program flow.

2.4.9. Cross-Platform Support

• The Arduino IDE works on Windows, macOS, and Linux, making it accessible across different

platforms.

2.5. Why do we use Arduino IDE in BMS

Using the Arduino IDE in a Battery Management System (BMS) development is a popular

approach, especially for prototyping and custom solutions. The Arduino platform allows you to

program microcontrollers for monitoring, controlling, and managing battery performance, making
 it a cost-effective and flexible tool. Below are some key areas where the Arduino IDE is utilized in

BMS design and implementation:

1. Battery Monitoring and Control

The Arduino IDE can be used to program the Arduino microcontroller to handle various tasks related

to battery monitoring and control. These include measuring key battery parameters like:

• Voltage: Monitoring individual cell voltage or pack voltage.

• Current: Measuring the charging/discharging current using sensors (e.g., ACS712 or INA219).

• Temperature: Using temperature sensors (e.g., thermistors or digital sensors like DS18B20) to

monitor battery temperature for safety.

• State of Charge (SoC): Estimating the charge remaining in the battery based on voltage and current

data.

2. Cell Balancing

In multi-cell battery packs, cell balancing ensures that all cells charge and discharge uniformly to

prevent overcharging or over-discharging individual cells. Arduino, using its GPIO pins and

libraries, can be programmed to perform active or passive cell balancing.

3. Battery Protection and Safety

Using Arduino IDE, you can program the microcontroller to implement battery protection

mechanisms such as:

• Overcharge protection: Stopping charging when the voltage exceeds a safe threshold.

• Overdischarge protection: Disabling the load when the battery voltage drops too low.

• Overcurrent protection: Detecting when the current exceeds safe limits and shutting off charging

or discharging.

• Thermal protection: Using temperature sensors to stop charging or discharging when the battery

temperature exceeds safe levels.

4. Current Sensing and Power Management

 Arduino can interface with current sensors like ACS712 or INA219 to measure the battery’s current

consumption during charging or discharging. This data is critical for calculating power, monitoring

energy consumption, and determining the State of Health (SoH) and State of Charge (SoC) of the

battery.

5. Communication Protocols (I2C, SPI, CAN Bus)

The Arduino IDE allows you to program the Arduino to communicate with other devices in the

BMS using communication protocols such as:

• I2C: Often used to connect current sensors (e.g., INA219) or temperature sensors.

• SPI: Commonly used for high-speed data transfer with components like external ADCs for more

accurate battery monitoring.

• CAN Bus: In more complex BMS setups, especially in electric vehicles (EVs), the Controller

Area Network (CAN) bus is used for communication between the BMS and other vehicle

components. Arduino can be programmed to interface with the CAN bus using shields and

libraries.

6. Data Logging and Visualization

With the Arduino IDE, you can program the Arduino to log battery data such as voltage, current,

and temperature over time. This data can be stored on an SD card or transmitted to a computer via

USB for real-time monitoring.

You can also use the Serial Plotter in the Arduino IDE to visualize battery data, such as voltage or

current trends, which is especially useful for diagnosing battery health.

7. State of Charge (SoC) and State of Health (SoH) Calculation

The Arduino IDE can be used to implement algorithms for calculating the State of Charge (SoC)

and State of Health (SoH) of the battery. These calculations often involve reading the voltage and

current data and applying Coulomb counting or voltage-based estimation.

8. Integration with IoT Systems

You can extend the functionality of the BMS by connecting the Arduino to an IoT platform. Using

Wi-Fi modules like ESP8266 or ESP32, you can send battery data to cloud platforms for remote

monitoring, notifications, or even control the battery system remotely.

2.6. Conclusion

Designing and managing a Battery Management System involves a range of software tools,

depending on the complexity of the project. PCB design tools like KiCad or EAGLE handle the

hardware design, while simulators like LTspice or Simulink ensure functionality through virtual

testing. Embedded software like Arduino IDE is crucial for programming the BMS controller, while

specialized simulation tools like ANSYS or Battery Design Studio provide deeper insights into

battery performance. Finally, data analysis and monitoring software ensure the BMS works

effectively in real-time applications.

The Arduino IDE is an intuitive and versatile platform for developing embedded systems projects

with Arduino microcontrollers. Its simplicity makes it accessible for beginners, while its

extensibility and support for external libraries allow more advanced users to build complex systems

like battery management systems, robotic controls, IoT devices, and more. Whether you’re a

hobbyist or a professional, the Arduino IDE provides an easy-to-learn yet powerful toolset for

programming and debugging microcontroller projects.

The Arduino IDE is a powerful tool for developing and managing Battery Management Systems,

from prototyping to small-scale applications. It allows you to monitor voltage, current, and

temperature, perform cell balancing, implement safety features, and even log and visualize data.

Arduino's flexibility, ease of use, and extensive library support make it a popular choice for BMS

development in projects ranging from simple battery packs to more complex energy storage

systems.
 Chapter 3: Hardware Requirements

3.1. Battery Management System (BMS)

The design and implementation of a Battery Management System (BMS) require various hardware

components to ensure proper functionality. The hardware plays a crucial role in monitoring, controlling,

and protecting the battery pack, making sure it operates safely and efficiently. Below is a list of the hardware

components typically used in a BMS, along with their descriptions and functionalities.

3.1.1 Battery Cells

• Description: The battery cells are the fundamental energy storage units. For this example, assume

the use of Li-ion cells, which are widely used in electric vehicles, portable electronics, and energy

storage systems.

• Specifications:

o Nominal Voltage (Li-ion): 3.7V per cell

o Capacity: Varies depending on the cell, usually 2000mAh to 3500mAh for consumer-

grade cells.

o Chemistries: Li-ion, NiMH, LiFePO4 (Lithium Iron Phosphate)

3.1.2 Battery Management System (BMS Board)

• Description: The BMS board is the central component that monitors the battery cells’ voltage,

current, and temperature. It protects the battery from overcharging, over-discharging, overcurrent,

and short circuits, and performs cell balancing.

• Functions:

o Voltage, current, and temperature sensing.

o Overvoltage, undervoltage, and overcurrent protection.

o Cell balancing (passive or active).

o Communication interface (I2C, CAN, etc.).

• Example Modules: 2S, 3S, 4S BMS boards for Li-ion or LiFePO4 cells.

3.1.3. Microcontroller (e.g., Arduino Uno)

• Description: The microcontroller interfaces with the BMS to gather data such as cell voltages,

current, temperature, and SOC. It processes this data and communicates with external devices like

a smartphone via Bluetooth.

• Specifications:

o 5V operating voltage.
 o 16MHz clock speed.

o Multiple GPIO pins for interfacing with sensors and Bluetooth modules.

• Functions: Data processing, analog-to-digital conversion (ADC), Bluetooth communication.

3.1.4 Bluetooth Module (e.g., HC-05 or HC-06)

• Description: The Bluetooth module allows wireless communication between the BMS and a

smartphone or other external devices, enabling real-time monitoring of battery parameters like

voltage, current, and SOC.

• Specifications:

o 3.3V to 5V operating voltage.

o Range of up to 10 meters.

• Functions: Wireless communication via serial protocol (UART).

3.1.4 Voltage Sensors (Voltage Divider Circuits)

• Description: Voltage sensors are used to measure the voltage of individual cells and the entire

battery pack. A simple voltage divider circuit can scale down higher voltages to a level readable by

the microcontroller’s ADC pins.

• Components:

o Resistors (typically in the kΩ range) for voltage division.

• Functions: Scaling high voltage (up to 30V) to the 0-5V range for measurement by the

microcontroller.
3.1.5 Current Sensors (e.g., ACS712)

• Description: The current sensor measures the charging and discharging current of the battery pack.

The ACS712 is a Hall-effect-based sensor that provides analog output proportional to the current

flowing through it.

• Specifications:

o Different variants for measuring 5A, 20A, or 30A.

o Provides analog output in the range of 0-5V.

• Functions: Measuring real-time current in the battery circuit.

3.1.6. Display (Optional, e.g., OLED or LCD)

• Description: A display unit (such as an OLED or LCD screen) can be added to the system to

provide real-time visualization of battery parameters such as voltage, current, SOC, and

temperature.

• Functions: Local display of important battery statistics, enhancing user interface.

3.1.7 Breadboard and Wires

• Description: Breadboards and jumper wires are used for prototyping the circuit. They allow for

easy assembly and testing of connections without soldering.

• Functions: Temporary circuit connections for testing and prototyping.

3.1.8 Power Supply/Charger

• Description: An appropriate charger or power supply is needed to recharge the battery pack. This

charger needs to be compatible with the battery chemistry and the number of cells in the series.

• Functions: Safe and efficient charging of the battery pack.

3.2 Circuit Diagram Overview

1. Battery Pack:

o Configuration: 2S2P (Two cells in series, two parallel strings of series cells).

o Connected to the BMS board.

2. BMS Board:

o Monitors each cell voltage.

o Provides protection and balancing.

o Connects to microcontroller for data transmission.

3. Microcontroller (Arduino Uno):

o Reads voltage and current data from sensors.

o Processes data and sends it to the Bluetooth module.

 o Interfaces with voltage sensors using ADC pins.

4. Voltage Divider Circuits:

o Connected between battery terminals and microcontroller ADC pins.

o Resistors scale down battery voltage for safe microcontroller measurement.

5. Current Sensor (ACS712):

o Connected between the battery and load (or charger).

o Analog output connected to microcontroller for current measurement.

6. Bluetooth Module:

o Communicates with microcontroller via serial protocol (TX/RX pins).

o Sends battery data wirelessly to a smartphone app.

 Chapter 4: PCB Connections & Code

4.1. Code:

#include <LiquidCrystal.h>
#include <SoftwareSerial.h>
SoftwareSerial BTSerial(10, 11); // RX | TX (Using SoftwareSerial on pins 10 and 11)

LiquidCrystal lcd(7, 8, 9, 10, 11, 12);

// Pin definitions
const int currentPin1 = A2; // ACS712 5A for Cell 1
const int currentPin2 = A3; // ACS712 5A for Cell 2
const int currentPin3 = A4; // ACS712 5A for cell 3
const int currentPin4 = A5; // ACS712 30A
const int voltagePin = A0; // Voltage Sensor connected to A4
const int voltagePin2 = A1;
const float vRef = 5.0; // Reference voltage of the Arduino
const float r1 = 30000.0; // Resistor R1 value in ohms
const float r2 = 7500.0; // Resistor R2 value in ohms
//const float acsOffset = 2.5; // ACS712 output at 0A (Vcc/2 for 5V)

// Calibration values for ACS712 (sensitivity in V/A)

const float sensitivity5A = 0.185; // 0.185 V/A for ACS712-05B
const float sensitivity30A = 0.066; // 0.066 V/A for ACS712-30A

// Reading the average of multiple readings to reduce noise

const int numReadings = 100; // Number of readings to average

void setup() {
[Link](9600); // opens serial port, sets data rate to 9600 bps
[Link](16, 2); // set up the LCD's number of columns and rows:
[Link]("DIGITAL V METER");
 delay(2000); // Wait for 2 seconds to show the title
[Link](); // Clear the LCD screen
}

void loop() {
float current1 = getAverageCurrent(currentPin1, sensitivity5A);
float current2 = getAverageCurrent(currentPin2, sensitivity5A);
float current3 = getAverageCurrent(currentPin3, sensitivity5A);
float current4 = getAverageCurrent(currentPin4, sensitivity30A);

// Read the voltage across the voltage divider

int voltageRaw1 = analogRead(voltagePin);
float vOut1 = voltageRaw1 * (vRef / 1023.0); // Convert to actual voltage
float cellVoltage1 = (vOut1 * ((r1 + r2) / r2)); // Calculate actual cell voltage

// Read the voltage across the voltage divider

int voltageRaw2 = analogRead(voltagePin2);
float vOut2 = voltageRaw2 * (vRef / 1023.0); // Convert to actual voltage
float cellVoltage2 = (vOut2 * ((r1 + r2) / r2)); // Calculate actual cell voltage

// Display the measured values

[Link]("Voltage: ");
[Link](cellVoltage1);
[Link](" V");

[Link]("Voltage 2: ");
[Link](cellVoltage2);
[Link](" V");
[Link]("Current Cell 1: ");
[Link](current1);
[Link](" A");
[Link]("Current Cell 2: ");
[Link](current2);
[Link](" A");

[Link]("Current Cell 3: ");

[Link](current3);
[Link](" A");

[Link]("Current Cell 4: ");

[Link](current4);
[Link](" A");

[Link]("Voltage Value1: ");

[Link](cellVoltage1);
[Link]("Voltage Value2: ");
[Link](cellVoltage2);
[Link]("Current Value1: ");
[Link](current1);
[Link]("Current Value2: ");
[Link](current2);
[Link]("Current Value3: ");
[Link](current3);
[Link]("Current Value4: ");
[Link](current4);

// Display the voltage on the LCD

[Link](0, 0);
[Link]("Voltage1 = ");
[Link](9, 0);
[Link](cellVoltage1,5);
 [Link]("Voltage2 = ");
[Link](9, 0);
[Link](cellVoltage2,5);
[Link]("Current 1 = ");
[Link](9, 0);
[Link](current1,5);
[Link]("Current 2 = ");
[Link](9, 0);
[Link](current2,5);
[Link]("Current 3 = ");
[Link](9, 0);
[Link](current3,5);
[Link]("Current 4 = ");
[Link](9, 0);
[Link](current4,5);

delay(1000); // Delay before next reading

}

// Function to read and calculate average current

float getAverageCurrent(int pin, float sensitivity) {
float currentSum = 0;
for (int i = 0; i < numReadings; i++) {
int rawValue = analogRead(pin);
float voltage = rawValue * (5.0 / 1023.0);
float current = (voltage - 2.5) / sensitivity; // 2.5V is zero current
currentSum += current;
delay(10)
}
return currentSum / numReadings;
}
4.2. Block Diagram:
 Chapter 5: Results and Conclusion

5.1. Result

5.1.1. Series and Parallel Battery Configuration Analysis:

• Series Connection: The study found that connecting batteries in series increases the voltage while

keeping the current constant. For instance, in a 2S2P configuration (two batteries in series and two

parallel groups), the combined voltage is the sum of the voltages of the individual cells. In our

project with Li-ion batteries, each with a nominal voltage of 3.7V, the series configuration produced

a total voltage of 7.4V.

• Parallel Connection: In the parallel configuration, the overall capacity (current rating) increased

while the voltage remained constant. With two 2.5Ah batteries connected in parallel, the current

capacity increased to 5Ah, while the output voltage remained at 3.7V.

5.1.2. Voltage and Current Measurements:

• Voltage Measurement: The use of Arduino Uno with a voltage sensor allowed accurate

measurement up to 30V. Real-time monitoring of individual cell voltages was implemented

successfully, providing essential data to prevent overcharging and deep discharge. The voltage

readings were relayed wirelessly via Bluetooth, ensuring that remote monitoring is possible.

• Current Measurement: Current measurement was achieved by taking an average of multiple current

readings for both individual Li-ion cells and the 2S2P battery pack. The BMS effectively managed

current distribution and provided accurate data, which is critical for performance analysis. The

current readings were used to evaluate discharge rates under different load conditions, and these

values aligned with expected theoretical outputs.

5.1.3. Battery Types and Performance:

• Li-ion Batteries: The study confirmed that Li-ion cells have high energy density, making them

suitable for portable electronics and electric vehicles. The cells demonstrated consistent

performance in terms of voltage stability and rechargeability.

• NiMH Batteries: NiMH cells, although offering lower energy density than Li-ion, exhibited

superior performance in terms of safety and longevity in high-temperature environments. However,

their higher self-discharge rate makes them less optimal for applications requiring long periods of

idle storage.

• LiFePO4 Batteries: LiFePO4 batteries were analyzed for their high thermal stability, safety, and

long cycle life. Despite having a lower nominal voltage (3.2V per cell), their high charge-discharge

efficiency and extended life cycle make them a robust option for applications requiring safety and

longevity.

5.1.4 Motor and Load Analysis:

• The power requirements of various motors were calculated based on battery ratings. For example,

a 7.4V battery pack was sufficient to power small DC motors, with current draw measured and

monitored under different load conditions. The study determined that the BMS effectively

prevented overcurrent situations, protecting both the motor and the battery from damage.

5.1.5 Power Management and Efficiency:

• Efficiency was measured based on the power loss in the battery during charge and discharge cycles.

The BMS maintained a high efficiency by controlling the charging process and preventing

overcharging or deep discharge, minimizing energy losses. The data showed that for Li-ion cells,

the charging efficiency remained above 90%, which was consistent with industry standards.
5.2. Conclusion:

5.2.1 Effective Battery Management System:

• The project successfully developed and tested a Battery Management System that could handle

essential functions, such as voltage and current measurement, protection against overcharging and

deep discharge, and efficient battery utilization. The BMS was able to monitor individual cells in a

multi-cell battery pack, providing accurate and reliable performance data. This demonstrates the

system's potential for use in electric vehicles, renewable energy storage systems, and portable

electronics.

5.2.2 Performance Comparison of Battery Types:

• Among the battery types tested, Li-ion batteries provided the best balance of energy density,

rechargeability, and performance. While NiMH batteries performed well in terms of thermal

stability, their high self-discharge rate was a drawback. LiFePO4 batteries emerged as a strong

contender in terms of safety and long life, though their lower energy density requires consideration

in applications where space and weight are constraints.

5.2.3 Motor and Load Compatibility:

• The results indicated that battery configurations could be tailored to meet the power requirements

of different loads. The study showed that careful management of series and parallel configurations

allows for optimizing power output for various motor types and loads. By calculating motor ratings

from battery ratings, the BMS provided an effective way to ensure that motors operate efficiently

and safely under varying conditions.

5.2.4 Arduino-Based Monitoring and Control:

• The integration of Arduino Uno for voltage and current measurement provided an accessible and

flexible solution for battery monitoring. The use of Bluetooth for wireless communication proved

reliable and useful for real-time data tracking, making it possible to manage battery performance
 remotely. This feature is critical in applications where direct access to the battery system is limited,

such as in electric vehicles or renewable energy systems.

5.2.5 Future Improvements:/

• While the BMS developed in this project performed effectively, there are opportunities for further

improvements. Incorporating more advanced microcontrollers with greater processing power could

enhance the real-time monitoring and control capabilities of the system. Additionally, the inclusion

of temperature sensors would provide additional data to further optimize battery performance and

safety.

• Future iterations could also focus on integrating energy storage from renewable sources, like solar

or wind, by optimizing charging and discharging algorithms to manage fluctuating power inputs

more efficiently.

5.2.6 Conclusion for Broader Applications:

• The results of this project suggest that the BMS design is scalable and could be adapted for use in

a variety of industries, including electric vehicles, aerospace, and renewable energy systems. With

further refinements and advancements, such a BMS could provide the foundation for energy-

efficient, safe, and reliable battery usage in a wide array of technological applications. By

continuing to improve battery chemistry and management techniques, the future of energy storage

looks promising and capable of supporting the growing demand for cleaner, more sustainable power

solutions.