Battery-powered electric propulsion systems are gaining importance in the electric car industry, as well as in the e-bike industry. These vehicles rely on battery packs that must always be used with an optimal electronic protection circuit to prevent the cells from overcharging or over-consumption.
Designing the right circuit is vital to ensure battery longevity. For a high voltage lithium battery pack, a BMS or Battery Management System has to be developed to monitor the performance of each cell and ensure that the battery will work properly.
A BMS is an electronic system that allows centralized control of lithium battery packs, which are arrays of cells arranged in a matrix. It also monitors its status, reporting all data, controlling the environment and making it work in balance.
The main functions of the BMS include:
Improved battery performance and longevity, the BMS optimizes battery life and capacity, ensuring efficient and prolonged operation.
The second function is the improvement of safety and protection, the BMS prevents overcharging and excessive discharge, as well as monitors the battery temperature, prioritizing safety.
Improve battery efficiency and energy delivery: the BMS ensures optimal charging and discharging processes, resulting in efficient energy utilization and consistent performance.
It is also responsible for battery monitoring: it estimates the state of charge (SoC) and state of health (SoH) during charging and discharging.
And last on the list, ensure better real-time monitoring of battery status by improving battery management capabilities.
A BMS system consists of two components:
Both components are encapsulated in modules connected to the cells by a complex network of wires.
The battery protection circuit module is a critical component of the BMS.
It consists of a balanced circuit together with additional circuits designed to protect the battery against overcharging, excessive discharging and high temperatures. These protections are essential to ensure safe and reliable battery operation by preventing the battery from operating outside its safe limits. The protection circuit module constantly monitors the battery voltage, current and temperature and takes corrective action if any of these parameters exceed safety limits.
Designing and building a custom BMS requires advanced knowledge in PCB design, electronic engineering and programming. Therefore, it is crucial to have the support of an experienced supplier.
REGNER is a reliable and experienced partner for electronic solutions. Our R&D, production and quality control engineers can develop state-of-the-art solutions that are ultra-light, rugged, and reliable.
There are several factors that our engineers consider when testing and selecting lithium-ion cells:
Starting with capacity/energy, which refers to the amount of charge a cell can store and deliver at a given voltage. Expressed in ampere-hours (Ah) or watt-hours (Wh). More energy translates into more autonomy for the e-bike.
The discharge rate, which is the rate at which a cell can supply current at a given voltage, measured in amperes (A) or C-rate. A higher discharge rate provides faster acceleration and better uphill performance.
Third, energy density, the energy that a cell can store per unit volume or mass. Measured in watt-hours per liter (Wh/L) or per kilogram (Wh/Km). The higher the density, the lighter and more compact the batteries can be.
The cycle life, which is the number of complete charge and discharge cycles before the capacity drops below 80% of its initial value. Longer life cycle means longer durability.
Finally, our engineers pay special attention to safety, which refers to the ability of a cell to resist damage, fire or explosion. Safety depends on the chemistry and structure of the cell, along with the built-in protection mechanisms.
Taking all these factors into account, our engineers subject the electric batteries to a series of quality tests to ensure their safety, performance and durability, including:
At REGNER, we are aware of the risks associated with lithium-ion batteries, such as overheating, short circuits and fires.s. For this reason, at our Aiguaviva plant we have implemented rigorous safety measures and properly trained all personnel.
The production of BMS for electric bicycles requires careful execution to ensure optimum performance, safety and durability. The entire process must be smooth and uneventful, resulting in the delivery of the highest quality products.
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Designing the right circuit is vital to ensure the longevity of the batteries, a Battery System has to be elaborated.
