Battery management system (BMS)

For a customer, we engineered an advanced Battery Management System (BMS). This groundbreaking system redefines battery management for large-scale applications, incorporating innovative technologies and safety certifications to ensure optimal performance and reliability.

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The customer approached us with a bold vision: to develop a BMS that would efficiently manage batteries in a large rack, providing enhanced control, safety, and data management capabilities. We embraced this challenge, leveraging our expertise and passion for innovation to create a truly exceptional solution.

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Key Innovations of the Battery Management System (BMS):

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1. BMS with ISO-SPI / ISO-CAN & RS485:The BMS incorporates advanced communication protocols, including ISO-SPI, ISO-CAN, and RS485. These protocols enable seamless data exchange between the BMS and the battery units, ensuring accurate monitoring, control, and synchronization of battery parameters.
2. Interlock and Redundant Power Supply:To enhance safety and reliability, the BMS features an interlock mechanism that shuts down the system in the event of a current fall of 50mA. This interlock ensures immediate response to potential faults, protecting the batteries and the overall application. Additionally, the BMS includes redundant power supply units (PSUs) for uninterrupted operation and system resilience.
3. SIL Certification and Isolated Components:The BMS design places significant emphasis on safety, incorporating isolated components to meet SIL (Safety Integrity Level) certification requirements. This isolation ensures the integrity and reliability of the system, mitigating risks and enhancing overall safety performance.
4. Little BMS Integration:The batteries within the rack are equipped with individual Little BMS (LTC BMS chip) controllers, responsible for cell-level monitoring and control. Our focus was on integrating these existing Little BMS controllers seamlessly into the overall battery management system, ensuring efficient coordination and operation between the big BMS and the individual battery units.
5. Smart Contactor and Daisy Chaining:The BMS includes a smart contactor that efficiently routes positive and negative connections, enabling daisy chaining of the batteries. This design simplifies wiring and enhances overall system scalability, enabling seamless integration and expansion of the battery rack.
6. ISO-CAN and Current Shunt Integration:The BMS integrates ISO-CAN technology, along with a current shunt from Victron, enabling accurate current measurements and monitoring. This integration ensures precise monitoring of battery performance and allows for real-time data logging.
7. Texas Instruments Safety MCU:The BMS utilizes a Texas Instruments safety MCU (Hercules) as the main control unit, offering robust performance and adherence to safety standards. This MCU ensures reliable and efficient operation of the BMS, supporting various communication protocols and advanced functionalities.
8. PCI-E Extension and RS485 Connectivity:To enable seamless integration with external systems, the BMS features a PCI-E extension for enhanced connectivity options. Additionally, the BMS incorporates RS485 connectivity, facilitating integration with a Raspberry Pi edge gateway. This gateway acts as an Energy Management System (EMS), providing data aggregation, remote access, and smart control capabilities.

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The collaboration between [Your Company Name] and the undisclosed customer showcases our dedication to pushing the boundaries of battery management technology. While the batteries within the rack already feature individual Little BMS controllers, our focus was on developing the big BMS to seamlessly integrate and coordinate with these controllers, ensuring efficient and reliable battery management at a system level.

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