Isolated Battery Management Systems (BMS)

Transparent electric car with a view of the battery
Battery Electric Vehicles (BEVs) and Plug-In Hybrid Electric Vehicles (PHEVs) rely on series-connected Lithium-Ion cells to deliver the high voltage needed by the traction motors. These high voltage (HV) stacks can range from forty-eight to around a hundred volts for mild hybrids with limited range up to several hundred volts for an electric vehicle with a range of hundreds of kilometers. Next-generation electric cars and trucks will use 800V stacks or more for an even longer range without recharging and for ultra-fast charging in a matter of minutes (a higher voltage means the charging current is lower, so the heat dissipated in the battery is less and the battery can accept more charging power). As each electric vehicle battery cell generates a nominal 3.7V-4.2V when fully charged, an 800V electric car battery will need approximately 240 cells connected in series.

HV Battery Stacks

For practical reasons, it is better to arrange batteries for electric cars in several separate battery packs, each containing from six to twenty-four cells. Smaller sized packs allow the maximum use of the available space in an irregularly shaped electric vehicle's battery enclosure to fit into a typical electric vehicle chassis. The use of battery packs also allows more freedom in selecting parallel/serial combinations to create different voltage/current profiles for different traction motor drivers. Additionally, if there is a single cell failure, it only affects one battery pack out of many and the EV's battery system can still function.

Cell Balancing

The cell voltage and energy capacity vary slightly between cells, so simply daisy-chaining all the cells together when charging EV batteries will create imbalances between the cells with some fully-charged while others still needing more charge. The overcharged cells can get hot, which could damage the cells and the battery pack. In a worst-case scenario, the battery pack could catch fire. To avoid this situation, cell monitoring ICs are used to individually monitor and control the charging (and discharging) profiles so all the cells are used to their full capacity without being damaged by undervoltage, overvoltage or overtemperature conditions. During the charging process, individual fully charged cells can be bypassed to allow the other cells in the stack to continue to be charged. This balancing process continues until all cells are fully charged to the same level. During discharge, the same balancing circuit can work to make certain that all the cells are equally discharged.

Battery Management Systems

The EV battery packs are stacked together to form the required high voltage and communicate with a central battery management system (BMS) via a communication bus, usually a CAN-bus which is prevalent in the automotive industry. The BMS monitors overall charging and discharging profiles and calculates the state of charge (SoC) and state of health (SoH) of the HV stack. It also monitors each pack's current, voltage and temperature to verify safe operation. As the number of cells in the HV battery increases, the amount of data that needs to be collected and processed also increases, but the system loop time requirements remain fixed. The CAN-bus must operate with high data rates (up to 25Mbps) and low propagation delays (between 50ns and 100ns).

Safety Isolation

All EVs must have a mechanical safety switch or contactor to disconnect the HV battery in case of an emergency. If the switch is placed in series with the high voltage output of the battery, then there still could be sufficient current flowing between the battery packs in the stack under a fault condition to cause a fire, so it is usually placed in the middle of the stack. This unusual arrangement (Figure 1) maximizes the overall safety but requires isolated communication lines to prevent current from bypassing the safety switch via the data bus connections.

A diagram showing a battery stack with an isolated data bus. The diagram illustrates how a safety switch is placed in the middle of the stack, and how isolated communication lines prevent current from bypassing the switch.

Fig 1. Battery stack with isolated data bus

Increasing Fault Tolerance with Isolated DC/DC Converters

The majority of cell balancing ICs incorporate an internal voltage regulator that uses the battery voltage to power both the IC and the isolated side of the data communication port, while the BMS controller powers the non-isolated side (red traces in Figure 1). However, with high voltage battery stacks consisting of many battery packs arranged in a parallel/series configuration, isolating each battery string's communication bus separately using isolated CAN-bus transceivers improves system reliability. In this case, isolated power is also required for the isolated CAN-bus side (Figure 2).

A diagram showing separate isolated power and bus connections for paralleled battery stacks. It highlights the use of isolated CAN-bus transceivers and the need for isolated power on the CAN-bus side.

Fig. 2: Separate isolated power and bus connections for paralleled battery stacks

RECOM offers the R05CTE05S isolated 5V-to-5V module specifically designed for isolated bus transceiver applications. It provides 1W of power in a compact 16 SOIC SMD package over a temperature range of -40°C up to +125°C, which makes it ideal for installation inside the battery compartment. The isolation grade is 3kVDC/1 minute, meaning that it can be used with 800V or higher battery stack voltages with ease. This design allows for future EV battery technology developments, as electric vehicle battery manufacturers are constantly looking to improve their products. To improve system fault tolerance, the output is protected against continuous short circuits, overcurrent, and overtemperature. An under-voltage lockout function means that the converter only starts up once the supply voltage exceeds 3.3V, avoiding data corruption issues during the power-up sequence of the BMS system.

Saving Cost with Isolated DC/DC Converters

A diagram showing a non-isolated transceiver, a digital isolator, and a DC/DC converter module working together.
Fig. 3: “Discrete” isolated CAN-bus interface solution
Isolated CAN bus transceivers with built-in DC/DC converters are available, but they are more expensive than their non-isolated counterparts and the choice of supplier is restricted. A more flexible and often more cost-effective alternative is to use a non-isolated transceiver with a digital isolator and a DC/DC converter module to build an isolated CAN-bus interface (Figure 3).

Although this solution uses more components, the choice of supplier is wider and the total cost of ownership (TCO) can be lower. A common question is, “how long do electric car batteries last?” One of the most important functions of the battery management system for electric vehicles is to prolong the lifetime of the battery packs by balancing the charging and discharging current through individual cells, bypassing defective cells and preventing the battery packs of plug-in electric vehicles from being accidentally overcharged or suffering a catastrophic deep discharge.

Thermistors are also built into each electric vehicle battery pack for proper battery thermal management, as temperature extremes can also seriously affect battery lifetime. However, without continuous and reliable communication between the EV battery and the battery management system, this protection cannot be guaranteed. Therefore, the isolation in RECOM’s RxxCTxxS products has undergone time dependent dielectric breakdown (TDDB) testing and has a projected insulation lifetime of more than 600 years.
Applications
  Series
1 DC/DC, 1 W, Single Output, SMD RxxCTExxS Series
Focus
  • Compact 10.35 x 7.5mm SMD package
  • Low profile (2.5mm)
  • 3kVDC/1min isolation
  • Low EMI emissions
2 DC/DC, 0.5 W, Single Output, SMD RxxCTxxS Series
Focus
  • Compact 10.3x7.5mm SMD package
  • 5kVAC reinforced isolation
  • 5V or 3.3V post-regulated, selectable outputs
  • Low EMI emissions