| | | | | | | | | Page | Errata | Addenda
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| Preface | xi | (X) | (+)
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| 1 Introduction | 1 | (X) | (+)
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| 1.1 Naming conventions | 1 | (X) | (+)
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| 1.1.1 Cells, batteries and packs | 1 | (X) | (+)
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| 1.1.2 Resistance | 1 | (X) | (+)
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| 1.2 Li-Ion cells | 1 | (X) | (+)
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| 1.2.1 Formats | 2 | (X) | (+)
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| 1.2.2 Chemistry | 3 | (X) | (+)
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| 1.2.3 Safety | 6 | (X) | (+)
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| 1.2.4 Safe operating area | 6 | (X) | (+)
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| 1.2.5 Efficiency | 6 | (X) | (+)
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| 1.2.5.1 Energy | 6 | (X) | (+)
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| 1.2.5.2 Charge | 7 | (X) | (+)
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| 1.2.6 Aging | 9 | (X) | (+)
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| 1.2.6.1 Calendar life | 9 | (X) | (+)
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| 1.2.6.2 Cycle life | 9 | (X) | (+)
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| 1.2.7 Modeling | 10 | (X) | (+)
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| 1.2.8 Unequal voltages is series strings | 12 | (X) | (+)
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| 1.3 Li-Ion BMSs | 15 | (X) | (+)
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| 1.3.1 BMS definition | 16 | (X) | (+)
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| 1.3.2 Li-Ion BMS functions | 16 | (X) | (+)
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| 1.3.3 Custom versus. off-the-shelf | 16 | (X) | (+)
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| 1.4 Li-Ion batteries | 18 | (X) | (+)
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| 1.4.1 SOC, DOD and capacity | 18 | (X) | (+)
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| 1.4.2 Balance and balancing | 22 | (X) | (+)
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| 1.4.2.1 Unbalance over time | 24 | (X) | (+)
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| 1.4.2.2 Starting unbalance | 26 | (X) | (+)
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| 1.4.2.3 Battery SOC versus cell SOC | 26 | (X) | (+)
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| 1.4.3 SOH | 31 | (X) | (+)
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| 2 BMS options | 35 | (X) | (+)
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| 2.1 Functionality | 35 | (X) | (+)
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| 2.1.1 CCCV chargers | 35 | (X) | (+)
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| 2.1.2 Regulators | 37 | (X) | (+)
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| 2.1.3 Meters | 38 | (X) | (+)
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| 2.1.4 Monitors | 39 | (X) | (+)
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| 2.1.5 Balancers | 40 | (X) | (+)
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| 2.1.6 Protectors | 41 | (X) | (+)
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| 2.1.7 Functionality comparison | 41 | (X) | (+)
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| 2.2 Technology | 41 | (X) | (+)
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| 2.2.1 Simple (analog) | 42 | (X) | (+)
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| 2.2.2 Sophisticated (digital) | 43 | (X) | (+)
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| 2.2.3 Technology comparison | 43 | (X) | (+)
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| 2.3 Topology | 44 | (X) | (+)
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| 2.3.1 Centralized | 44 | (X) | (+)
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| 2.3.2 Modular | 45 | (X) | (+)
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| 2.3.3 Master-slave | 46 | (X) | (+)
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| 2.3.4 Distributed | 47 | (X) | (+)
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| 2.3.5 Topology comparison | 49 | (X) | (+)
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| 3 BMS functions | 51 | (X) | (+)
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| 3.1 Measurement | 51 | (X) | (+)
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| 3.1.1 Voltage | 52 | (X) | (+)
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| 3.1.1.1 Methods | 52 | (X) | (+)
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| 3.1.1.2 Rate | 52 | (X) | (+)
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| 3.1.1.3 Accuracy | 53 | (X) | (+)
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| 3.1.1.4 Isolation | 53 | (X) | (+)
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| 3.1.2 Temperature | 52 | (X) | (+)
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| 3.1.3 Current | 54 | (X) | (+)
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| 3.1.3.1 Current shunt | 55 | (X) | (+)
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| 3.1.3.2 Hall effect sensor | 57 | (X) | (+)
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| 3.2 Management | 58 | (X) | (+)
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| 3.2.1 Protection | 58 | (X) | (+)
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| 3.2.1.1 Monitored conditions | 58 | (X) | (+)
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| 3.2.1.1.1 Pack current | 58 | (X) | (+)
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| 3.2.1.1.2 Cell voltage | 60 | (X) | (+)
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| 3.2.1.1.3 Pack temperature | 60 | (X) | (+)
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| 3.2.1.1.4 Pack voltage | 61 | (X) | (+)
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| 3.2.1.2 Current interruption | 61 | (X) | (+)
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| 3.2.1.2.1 Request for interruption | 61 | (X) | (+)
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| 3.2.1.2.2 Direct interruption | 63 | (X) | (+)
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| 3.2.2 Thermal management | 63 | (X) | (+)
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| 3.2.2.1 Heating | 63 | (X) | (+)
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| 3.2.2.2 Cooling | 64 | (X) | (+)
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| 3.2.3 Balancing - Cell balance interactive tool | 64 | (X) | (+)
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| 3.2.3.1 Balancing algorithms | 65 | (X) | (+)
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| 3.2.3.1.1 Voltage based | 66 | (X) | (+)
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| 3.2.3.1.2 Final voltage based | 66 | (X) | (+)
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| 3.2.3.1.3 SOC history based | 68 | (X) | (+)
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| 3.2.3.1.4 Algorithm comparison | 71 | (X) | (+)
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| 3.2.3.1.5 Top versus mid balancing | 71 | (X) | (+)
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| 3.2.3.1.6 Top versus bottom balancing | 73 | (X) | (+)
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| 3.2.3.2 Balance current requirements | 76 | (X) | (+)
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| 3.2.3.2.1 Gross balance | 76 | (X) | (+)
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| 3.2.3.2.2 Maintenance balance | 77 | (X) | (+)
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| 3.2.3.2.3 Conclusions | 79 | (X) | (+)
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| 3.2.3.3 Active versus. passive balance | 79 | (X) | (+)
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| 3.2.3.4 Active balance techniques | 83 | (X) | (+)
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| 3.2.4 Redistribution | 84 | (X) | (+)
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| 3.2.4.1 Comparison between balancing and redistribution | 85 | (X) | (+)
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| 3.2.4.2 Converter power | 85 | (X) | (+)
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| 3.2.4.3 Redistribution versus. additional cells | 86 | (X) | (+)
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| 3.2.4.4 Conclusions | 87 | (X) | (+)
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| 3.2.5 Distributed charging | 87 | (X) | (+)
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| 3.3 Evaluation | 89 | (X) | (+)
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| 3.3.1 State Of Charge and Depth Of Discharge | 89 | (X) | (+)
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| 3.3.1.1 Voltage translation | 89 | (X) | (+)
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| 3.3.1.2 Coulomb counting | 90 | (X) | (+)
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| 3.3.1.3 Combining the two techniques | 92 | (X) | (+)
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| 3.3.2 Capacity | 95 | (X) | (+)
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| 3.3.3 Resistance | 96 | (X) | (+)
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| 3.3.4 State Of Health (SOH) | 97 | (X) | (+)
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| 3.4 External communications | 97 | (X) | (+)
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| 3.4.1 Dedicated analog wire | 98 | (X) | (+)
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| 3.4.1.1 Inputs | 98 | (X) | (+)
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| 3.4.1.2 Outputs | 99 | (X) | (+)
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| 3.4.2 Dedicated digital wire | 99 | (X) | (+)
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| 3.4.2.1 Inputs | 99 | (X) | (+)
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| 3.4.2.2 Outputs | 100 | (X) | (+)
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| 3.4.3 Data link | 102 | (X) | (+)
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| 3.4.3.1 RS232 | 103 | (X) | (+)
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| 3.4.3.2 CAN Bus | 103 | (X) | (+)
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| 3.4.3.3 Ethernet | 104 | (X) | (+)
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| 3.4.3.4 USB | 104 | (X) | (+)
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| 3.4.3.5 Wireless data link | 105 | (X) | (+)
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| 3.5 Logging and telemetry | 105 | (X) | (+)
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| 4 Off-the-shelf BMSs - Up-to-date list | 107 | (X) | (+)
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| 4.1.1 Simple | 107 | (X) | (+)
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| 4.1.1.1 Regulators | 108 | (X) | (+)
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| 4.1.1.2 Balancers | 108 | (X) | (+)
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| 4.1.1.2.1 Clean Power Auto | 109 | (X) | (+)
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| 4.1.1.2.2 Elithion | 109 | (X) | (+)
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| 4.1.1.2.3 EV Power | 109 | (X) | (+)
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| 4.1.1.3 Protectors | 110 | (X) | (+)
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| 4.1.2 Sophisticated | 111 | (X) | (+)
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| 4.1.2.1 Meters and monitors | 111 | (X) | (+)
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| 4.1.2.1.1 Electric Blue Motors | 111 | (X) | (+)
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| 4.1.2.1.2 Guantuo Power | 112 | (X) | (+)
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| 4.1.2.1.3 JK Hall | 112 | (X) | (+)
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| 4.1.2.2 Balancers and protectors | 113 | (X) | (+)
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| 4.1.2.2.1 Black Sheep Technology | 113 | (X) | (+)
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| 4.1.2.2.2 Clayton Power | 114 | (X) | (+)
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| 4.1.2.2.3 Elithion | 114 | (X) | (+)
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| 4.1.2.2.4 EVPST | 115 | (X) | (+)
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| 4.1.2.2.5 Genasun | 115 | (X) | (+)
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| 4.1.2.2.6 Lithium Balance | 115 | (X) | (+)
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| 4.1.2.2.7 REAP | 117 | (X) | (+)
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| 4.1.3 Cell manufacturers' BMSs | 117 | (X) | (+)
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| 4.1.3.1 Elite Power / EVPST | 117 | (X) | (+)
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| 4.1.3.2 Kokam / N Tech | 118 | (X) | (+)
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| 4.1.3.3 Thundersky / Ningbo Yangming | 118 | (X) | (+)
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| 4.1.3.4 Valence | 118 | (X) | (+)
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| 4.1.4 Comparison | 118 | (X) | (+)
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| 5 Custom BMS design | 121 | (X) | (+)
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| 5.1 Using BMS ASICs | 121 | (X) | (+)
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| 5.1.1 BMS ASIC selection - Up-to-date list | 121 | (X) | (+)
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| 5.1.2 BMS ASIC comparison | 124 | (X) | (+)
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| 5.2 Analog BMS design | 125 | (X) | (+)
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| 5.2.1 Analog regulator | 125 | (X) | (+)
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| 5.2.1.1 Zener diode | 125 | (X) | (+)
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| 5.2.1.2 Integrated circuit | 127 | (X) | (+)
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| 5.2.2 Analog monitor | 127 | (X) | (+)
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| 5.2.2.1 Distributed BMS | 128 | (X) | (+)
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| 5.2.2.1.1 NO, parallel bus | 128 | (X) | (+)
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| 5.2.2.1.2 NC, series bus | 129 | (X) | (+)
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| 5.2.2.1.3 Single bus | 132 | (X) | (+)
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| 5.2.2.1.4 Cell circuit | 134 | (X) | (+)
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| 5.2.2.2 Localized BMS | 135 | (X) | (+)
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| 5.2.2.2.1 Multiplexed circuit with generic ICs | 135 | (X) | (+)
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| 5.2.2.2.2 LTC6801 fault detector | 137 | (X) | (+)
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| 5.2.2.2.3 MAX1894 / MAX1924 protector | 138 | (X) | (+)
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| 5.2.2.2.4 MAX11080 fault detector | 138 | (X) | (+)
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| 5.2.3 Analog balancer | 138 | (X) | (+)
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| 5.2.3.1 Generic ICs | 139 | (X) | (+)
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| 5.2.3.2 DS series, DS2726 | 139 | (X) | (+)
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| 5.2.3.3 bq76pl536 BMS front end | 141 | (X) | (+)
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| 5.2.3.4 bq76pl537 BMS front end | 144 | (X) | (+)
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| 5.2.4 Analog protector | 144 | (X) | (+)
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| 5.3 Ready made, digital BMS designs | 144 | (X) | (+)
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| 5.3.1 ATMEL's BMS processor | 144 | (X) | (+)
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| 5.3.2 Elithion's BMS chip set | 145 | (X) | (+)
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| 5.3.3 National Semiconductors' complete BMS | 146 | (X) | (+)
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| 5.3.4 Peter Perkin's open source BMS | 147 | (X) | (+)
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| 5.3.5 Texas Instruments' bq29330 / bq20z90 | 149 | (X) | (+)
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| 5.3.6 Texas Instruments' bq78PL114 / bq76PL102 | 151 | (X) | (+)
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| 5.4 Custom digital BMS design | 152 | (X) | (+)
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| 5.4.1 Voltage and temperature measurement | 152 | (X) | (+)
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| 5.4.1.1 Distributed measurement | 153 | (X) | (+)
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| 5.4.1.2 Localized measurement | 156 | (X) | (+)
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| 5.4.1.2.1 Multiplexed measurement | 156 | (X) | (+)
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| 5.4.1.2.2 General purpose ICs versus ASICs | 158 | (X) | (+)
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| 5.4.1.2.3 Digital BMS using general purpose ICs | 158 | (X) | (+)
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| 5.4.1.2.4 Digital BMS ASICs | 161 | (X) | (+)
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| 5.4.1.2.4.1 Analog Devices' AD7280 | 163 | (X) | (+)
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| 5.4.1.2.4.2 Atmel's ATA6870 | 163 | (X) | (+)
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| 5.4.1.2.4.3 Intersil's ISL9216 / 17 | 167 | (X) | (+)
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| 5.4.1.2.4.4 Linear Technology's LTC6802-1 | 167 | (X) | (+)
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| 5.4.1.2.4.5 Linear Technology's LTC6802-2 | 168 | (X) | (+)
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| 5.4.1.2.4.6 Maxim's MAX11068 | 171 | (X) | (+)
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| 5.4.1.2.4.7 O2Micro's OZ890 | 173 | (X) | (+)
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| 5.4.1.2.4.8 Texas Instruments' bq76pl536 / bq76pl537 | 173 | (X) | (+)
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| 5.4.1.2.5 Redundant protection ASICs | 174 | (X) | (+)
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| 5.4.2 Current measurement | 175 | (X) | (+)
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| 5.4.2.1 Current shunt | 175 | (X) | (+)
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| 5.4.2.2 Hall effect sensor | 176 | (X) | (+)
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| 5.4.3 Evaluation | 178 | (X) | (+)
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| 5.4.3.1 SOA evaluation | 178 | (X) | (+)
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| 5.4.3.1.1 CCL and HLIM | 178 | (X) | (+)
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| 5.4.3.1.1.1 Maximum cell voltage | 179 | (X) | (+)
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| 5.4.3.1.1.2 Cell temperature | 180 | (X) | (+)
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| 5.4.3.1.1.3 Battery charge current | 180 | (X) | (+)
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| 5.4.3.1.1.4 Pack voltage | 182 | (X) | (+)
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| 5.4.3.1.2 DCL and LLIM | 182 | (X) | (+)
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| 5.4.3.2 SOC and DOD estimation | 183 | (X) | (+)
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| 5.4.3.3 Resistance calculation | 187 | (X) | (+)
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| 5.4.3.4 Capacity measurement | 188 | (X) | (+)
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| 5.4.3.5 SOH estimation | 189 | (X) | (+)
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| 5.4.3.6 Diagram | 191 | (X) | (+)
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| 5.4.4 Communications | 192 | (X) | (+)
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| 5.4.4.1 Dedicated wire | 192 | (X) | (+)
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| 5.4.4.1.1 Digital | 193 | (X) | (+)
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| 5.4.4.1.1.1 Outputs | 193 | (X) | (+)
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| 5.4.4.1.1.2 Inputs | 194 | (X) | (+)
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| 5.4.4.1.2 Analog | 195 | (X) | (+)
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| 5.4.4.2 Data link | 195 | (X) | (+)
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| 5.4.4.2.1 Serial | 196 | (X) | (+)
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| 5.4.4.2.2 CAN Bus | 196 | (X) | (+)
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| 5.4.4.2.2.1 Implementation | 196 | (X) | (+)
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| 5.4.4.2.2.2 Standard traction pack messages | 198 | (X) | (+)
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| 5.4.4.2.2.3 SAE J1939 standard | 198 | (X) | (+)
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| 5.4.4.2.2.4 PIDs | 198 | (X) | (+)
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| 5.4.4.3 Display | 200 | (X) | (+)
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| 5.4.4.3.1 LEDs | 200 | (X) | (+)
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| 5.4.4.3.2 Fuel gauge | 201 | (X) | (+)
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| 5.4.4.3.3 Full display | 201 | (X) | (+)
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| 5.4.5 Optimization | 202 | (X) | (+)
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| 5.4.5.1 Balancing | 202 | (X) | (+)
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| 5.4.5.1.1 Passive | 204 | (X) | (+)
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| 5.4.5.1.2 Active | 204 | (X) | (+)
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| 5.4.5.1.2.1 Cell-to-cell | 204 | (X) | (+)
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| 5.4.5.1.2.1.1 Capacitor | 204 | (X) | (+)
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| 5.4.5.1.2.1.2 Inductor | 206 | (X) | (+)
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| 5.4.5.1.2.1.3 Transformer | 206 | (X) | (+)
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| 5.4.5.1.2.2 Cell-to-battery | 206 | (X) | (+)
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| 5.4.5.1.2.3 Battery-to-cell | 208 | (X) | (+)
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| 5.4.5.1.2.4 Bidirectional | 209 | (X) | (+)
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| 5.4.5.2 Redistribution | 201 | (X) | (+)
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| 5.4.6 Switching | 215 | (X) | (+)
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| 5.4.6.1 Contactors | 216 | (X) | (+)
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| 5.4.6.2 Transistors | 217 | (X) | (+)
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| 5.4.7 Logging | 218 | (X) | (+)
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| 5.5 Cell interface | 219 | (X) | (+)
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| 5.5.1 Non-distributed | 219 | (X) | (+)
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| 5.5.2 Distributed | 220 | (X) | (+)
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| 5.5.2.1 Small cylindrical cells | 220 | (X) | (+)
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| 5.5.2.2 Prismatic cells | 222 | (X) | (+)
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| 5.5.2.3 Large cylindrical cells | 224 | (X) | (+)
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| 5.5.2.4 Pouch cells | 224 | (X) | (+)
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| 5.6 Distributed charging | 226 | (X) | (+)
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| 6 Deploying a BMS | 229 | (X) | (+)
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| 6.1 Installing | 229 | (X) | (+)
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| 6.1.1 Battery pack design | 229 | (X) | (+)
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| 6.1.1.1 Pack layout | 229 | (X) | (+)
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| 6.1.1.1.1 Cells in parallel versus batteries in parallel | 229 | (X) | (+)
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| 6.1.1.2 Battery layout | 232 | (X) | (+)
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| 6.1.1.3 Battery assembly | 234 | (X) | (+)
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| 6.1.1.3.1 Balancing before assembly | 234 | (X) | (+)
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| 6.1.1.3.2 Cell containment | 234 | (X) | (+)
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| 6.1.1.3.3 Cell isolation | 235 | (X) | (+)
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| 6.1.1.4 BMS placement | 236 | (X) | (+)
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| 6.1.1.5 Power circuits | 236 | (X) | (+)
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| 6.1.1.5.1 Power connection fastening | 236 | (X) | (+)
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| 6.1.1.5.2 Current splitter | 238 | (X) | (+)
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| 6.1.1.5.3 Source and load current sensing | 238 | (X) | (+)
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| 6.1.1.5.4 Current shunt wiring | 239 | (X) | (+)
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| 6.1.1.5.5 Contactors and precharge | 240 | (X) | (+)
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| 6.1.1.5.5.1 Function | 241 | (X) | (+)
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| 6.1.1.5.5.2 Operation | 241 | (X) | (+)
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| 6.1.1.5.5.3 Contactors selection | 241 | (X) | (+)
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| 6.1.1.5.5.4 Precharge relay selection | 242 | (X) | (+)
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| 6.1.1.5.5.5 Relay selection | 242 | (X) | (+)
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| 6.1.2 BMS connections to pack | 243 | (X) | (+)
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| 6.1.2.1 Wires and cables | 243 | (X) | (+)
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| 6.1.2.1.1 High voltage communication wires | 244 | (X) | (+)
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| 6.1.2.1.2 Low voltage communication cables | 244 | (X) | (+)
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| 6.1.2.1.3 High voltage tap wires | 245 | (X) | (+)
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| 6.1.2.2 Placement across adjacent cells | 245 | (X) | (+)
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| 6.1.3 BMS connections to system | 247 | (X) | (+)
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| 6.1.3.1 General requirements | 247 | (X) | (+)
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| 6.1.3.2 Chargers | 247 | (X) | (+)
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| 6.1.3.3 Motor controllers | 249 | (X) | (+)
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| 6.1.3.4 Grid connected inverters / chargers | 251 | (X) | (+)
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| 6.1.3.5 Fuel gauges | 251 | (X) | (+)
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| 6.2 Configuring | 252 | (X) | (+)
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| 6.2.1 Cell configuration | 252 | (X) | (+)
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| 6.2.2 Pack configuration | 252 | (X) | (+)
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| 6.2.3 System configuration | 253 | (X) | (+)
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| 6.3 Testing | 253 | (X) | (+)
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| 6.4 Troubleshooting | 255 | (X) | (+)
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| 6.5 Using | 256 | (X) | (+)
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| Acronyms and Abbreviations | 257 | (X) | (+)
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| Glossary | 261 | (X) | (+)
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| About the author | 269 | (X) | (+)
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| Index | 271 | (X) | (+)
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