Batteries & Fuel Cells
the power terminals, which can readily be made by robots in an automated process. By eliminating manual labour, OEMs also eliminate the safety risks to assembly line workers (see Figure 2).
In GM’s implementation of the wBMS technology, the scalable architecture of the Ultium modules also helps lower the cost of the battery pack to GM. While the Ultium battery had its debut appearance in 2021, the modules will be deployed across the range of GM vehicles, not only in heavy duty vehicles but also in all road cars, from performance and premium cars to small vehicles. As Kent Helfrich, GM executive director of Global Electrification and Battery Systems, mentioned in a September 2020 press announcement, “Scalability and complexity reduction are a theme with our Ultium batteries - the wireless management system is the critical enabler of this amazing flexibility.”
There are, then, many strong reasons for auto manufacturers to replace a BMS’s wires with robust wireless technology in new EV battery systems. But the advantages of Analog Devices’ wBMS technology extend beyond the point at which a new car appears for sale on a franchised dealer’s forecourt. 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. 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. Second life - the lifetime of a future EV’s battery will likely exceed that of the vehicle itself: Elon Musk from Tesla estimates the typical lifetime of the battery at the equivalent of “1 million miles” before it totally fails. So now 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 creates a new source of value for EV manufacturers, which are responsible for the recycling or disposal of the batteries in scrapped EVs.
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
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the wBMS-based battery has been run over hundreds of thousands of kilometres in more than 100 test vehicles, on- and off-road, and in environments ranging from desert to the frozen north and under the toughest conditions. Proven reliable and successfully passing all OEM security and robustness qualifications, it will be in a wide range of passenger vehicles soon.
With wBMS, Analog Devices also supports automotive manufacturers’ programmes for compliance with the ISO 26262 functional safety standard. The radio technology and 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 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 what source has sent a message.
Lifetime management of the value of the battery
Figure 2. wBMS technology eliminates the signal wiring harness to enable automated, robotic production of complete battery packs.
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 of second life modules in their next application, and the provision of a detailed set of specifications for each module on sale. The data’s ready availability increases the resale value of the modules.
Complete wireless system for battery data acquisition The wBMS technology draws on two longstanding fields in which Analog Devices has leading market positions: sensing and measurement and RF communications. The wBMS technology 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.
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In addition to the wireless section, each wCMC unit includes a best-in-class battery management system that performs highly accurate measurements of various battery parameters so that the applications processing unit can analyse the SOC and SOH of the batteries.
A robust communications architecture
The wireless network protocol implemented by Analog Devices in the wBMS system has the automotive industry’s requirement for reliability, safety, and security at its core. Unlike consumer-oriented wireless technologies such as Bluetooth or Wi-Fi networking, the wBMS solution, based on network-wide time synchronisation technology, puts the emphasis on achieving reliable and secure communication under all operating conditions, as required in automotive applications.
The use of wBMS in a mass production EV from General Motors is proof of its reliability in the harshest environments:
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 performance and safety, and maximise value. The entire system, including the interactions between the battery modules’ cell monitoring units and the ECU, are handled by the Analog Devices technology, with configuration settings defined by the manufacturer. The wBMS technology is also backed by the Analog Devices Battery Lifecycle Insight Service (BLIS) technology. This provides edge-and cloud-based 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 electric vehicle business strategies, and help accelerate the market’s shift toward a low carbon, sustainable future for personal mobility.
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Anmar Frangoul. “VW to Ramp Up Battery Cell Production with Six ‘Gigafactories’ in Europe.” CNBC, March 2021:
https://www.cnbc.com/2021/03/15/vw-to-
ramp-up-battery-production-with-six-gigafactories-in-europe-.html
Hummer EV Product Page. GMC, 2021.
https://www.gmc.com/electric/hummer-ev/pickup-trucks-suvs Components in Electronics April 2026 35
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