Advancements in Battery Monitoring Systems for Electric Vehicles

As electric vehicles (EVs) become increasingly prevalent in the automotive industry, there is a growing demand for efficient and effective battery monitoring systems (BMS) to ensure the safety and performance of EV battery packs. This article will explore the latest developments in BMS technology and their impact on the design and layout of EV battery packs.

A crucial aspect of BMS technology is its influence on the design and layout of vehicle packs. The type and positioning of sensors that record parameters such as temperature and current are affected by the BMS. A well-conceived BMS can simplify the expansion or contraction of the module count of a pack to accommodate different models, as well as reducing the Bill of Materials (BoM) and manufacturing time.

For instance, Hyundai’s E-GMP platform utilizes a BMS for each module, comprising a compact PCB at the end of the (pouch) cells, which interfaces with a cell monitoring unit responsible for four modules, located in the central spine of the pack. This configuration results in a relatively simple and easily expandable modular low-voltage layout within the pack.

Efforts are underway to streamline the low-voltage wiring inside a pack to lower cost, weight, and volume, while upholding safety and performance. This includes the development of solutions to simplify individual cell monitoring, such as the use of thin foil sensors for temperature and pressure monitoring.

Furthermore, the adoption of wireless sensors is an intriguing development that addresses the issue of wiring complexity and data transfer requirements for individual cell monitoring. Companies like Dukosi and Marelli have produced wireless battery monitoring systems that rely on near-field communication (NFC) and operate in the 2.4GHz range, respectively, to transfer cell health data and eliminate the need for extensive wiring within the pack.

The use of wireless BMS not only reduces wiring volume but also eliminates the necessity for custom harnesses from model to model, making it easier to adapt pack configurations. Additionally, the implementation of a wireless solution can significantly reduce the mass of a pack’s internal wiring.

In conclusion, the ongoing advancements in battery monitoring systems for electric vehicles are playing a crucial role in simplifying the design and layout of EV battery packs. From the simplification of low-voltage wiring to the development of wireless monitoring solutions, these technologies are essential for enhancing the safety, performance, and adaptability of EV battery systems. As the demand for electric vehicles continues to grow, the significance of innovative BMS technology cannot be overstated.