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POWER
FEATURE
nagement – giVing Car ew CompetitiVe edge
• Battery assembly – the only connections that a battery module requires are the power terminals, which can readily be made in a highly automated process. By eliminating manual labour for assembly and testing, this also avoids safety risks to assembly line workers (see Figure 2). Furthermore, the modules can also be tested and matched before installing inside the battery.
Figure 2. The wBMS eliminates the BMS signal wiring harness to enable automated, robotic production of battery packs
and connectors can potentially suffer from a mechanical failure especially under vibration and shock conditions. In other words, wires increase development
effort, manufacturing cost and weight while also reducing mechanical reliability and usable space. This results in reduced driving range. By removing the wiring harness, the car manufacturer gains new flexibility to meet a vehicle’s design requirements for the form factor of its battery pack. The complexity of a battery’s wiring harness
also makes the assembly of a battery pack difficult and expensive: wired packs have to be assembled and the connections have to be terminated manually. This is a costly and hazardous process because high voltage EV battery modules are supplied charged. To maintain the safety of the assembly process and to protect production line workers, rigorous safety protocols are applied. There are therefore many reasons for OEMs
to introduce a robust wireless technology to new EV battery system platforms.
wBmS – a new Smart approaCh
The wBMS is a complete solution that is easy for the automotive manufacturer to integrate into a battery pack design. It includes a wireless cell monitoring controller (wCMC) unit for each battery module and a wireless manager unit to control the communications network, which connects multiple battery modules wirelessly to the ECU. Beside the wireless section, each wCMC unit includes a BMS that performs highly accurate measurements of various battery parameters so that the applications processing unit can analyse the SOC and SOH of the batteries. While the wBMS technology has taken full
advantage of eliminating the wiring harness design and assembly issue, there are further areas within the battery lifecycle where additional value will be generated:
• Servicing – secure wireless capability means that the condition of the battery pack can be conveniently analysed by diagnostics equipment in an authorised garage without touching the pack. If a malfunction is detected, a faulty module can easily be removed and replaced. A wireless configuration simplifies installation of a new module in the battery system.
• Second life – by the increasing number of vehicles, a market is emerging for second life batteries recovered from scrapped EVs and repurposed for applications such as renewable energy storage systems and electric power tools. This additionally creates a new source of value for EV manufacturers, which are responsible for the recycling or disposal of the batteries in scrapped EVs, since wBMS allows a simpler integration of the modules for second life applications.
• Disposal – the recyclable metal and potentially hazardous materials inside a battery pack require approved and regulated disposal arrangements. The simple connections and absence of a communications wiring harness make removal of battery modules easier and quicker than that of a wired battery.
• Data management – the wBMS technology makes it easy to read out critical battery data from each intelligent module: this means that the condition of the batteries can be determined individually. This data can, for instance, provide information about the SOC and SOH of a module. In combination with data from when the module was originally produced, this allows the optimal usage in its second life application and the provision of a detailed set of specifications for each module on sale. The ready availability of these data increases the resale value of the modules.
CompLete SoLutionS for wBmS
The wireless network protocol implemented by ADI in the wBMS system has the automotive industry’s requirement for reliability, safety and security under all operating conditions based on the network-wide time synchronisation technology. The use of the wBMS in a mass production EV from General Motors is proof of its reliability in the harshest environments: the wBMS-based battery has been run over hundreds of thousands of kilometres in more than 100
test vehicles, on-road and off-road, and in environments ranging from a desert to the frozen north and under the toughest conditions. With the wBMS, ADI also supports automotive
manufacturers’ programs in compliance with the ISO 26262 functional safety standard. The radio technology and the networking protocol have been developed in such a way that the system is resilient in noisy environments and provides secure communication between the monitoring units and the manager using a sophisticated encryption technology. The security measures avoid spoofing of data transmitted on the wireless network by an unintended recipient such as a criminal or hacker. Furthermore, the transmitted data are received without any modification of the contents, and the intended recipient knows exactly which source has sent a message.
Lifetime management of the VaLue of the Battery
Across the entire battery pack’s lifetime, from initial assembly through disposal to second life, the wBMS capability embedded in the battery pack ensures that the vehicle’s manufacturer and its owner can easily track the condition of the battery, maintain the performance and safety, and maximise the value. The entire system, including the interactions between the battery modules’ cell monitoring units and the ECU, is handled by ADI’s technology, with configuration settings defined by the manufacturer. The wBMS technology is also backed by ADI’s
battery lifecycle insight service (BLIS) technology. This provides edge-based and cloud-based data software to support traceability, production optimisation, monitoring in storage and transit, early failure detection, and lifetime extension. Together, the wBMS and BLIS technologies enable automotive manufacturers to gain higher returns on their investments in battery pack development and production, improve the economics of their EV business strategies, and help accelerate the market’s shift toward a low carbon, sustainable, future for personal mobility. The key to designing and enabling such battery
solutions with wBMS are system understanding as well as methods and tools that support the design and technologies as described before. AVL offers the full range of simulation, testing, engineering capabilities, and experience to successfully drive these innovations together with their customers and bring them into the market by making them ready for series production. AVL is currently working on battery ecosystem
solutions through developing data analytics methodologies, predictive functionalities supported by using virtual development, and vehicle and battery data in order to increase the lifetime and performance of batteries.
Analog Devices
www.analog.com
DECEMBER/JANUARY 2023 DESIGN SOLUTIONS 13
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