D3 2 Battery Management System of the cells developed v2.0 PU · D3.2 – Battery management System of the cells developed (PU) Page 5/18 1 Introduction 1.1 This Document This document

Development of novel SOlid MAterials for high power Li polymer BATteries (SOMABAT).

Recyclability of components.

Gran Agreement No. NMP3-SL-2010-266090

Contact information

Project coordinator Mayte Gil Agustí [email protected]

Project partners 1. Asociación Instituto

Tecnológico de la Energía (ITE)

2. Université de Liège (ULG) 3. Kompetenzzentrum – Das

virtuelle Fahrzeug Forschungsgesellschaft mbH (VIF)

4. Kiev National University of Technologies and Design (KNUTD)

5. Institute of Chemistry Timisoara of Romanian Academy (ICT)

6. Cleancarb (CCB) 7. Centro Superior de

Investigaciones Científicas (CSIC)

8. Recupyl (RE) 9. Accurec (AC) 10. Lithium Balance (LB) 11. Cegasa Group (CEGASA) 12. Umicore (UMI) 13. Atos Origin Sociedad

Anónima Española (ATOS)

Collaborative Project

Joint call with Energy, Environment and Transport FP7-GC-2010-ELECTROCHEMICAL STORAGE

D3.2 – Battery management System of the cells developed (PU)

Due date of deliverable: 31-08-2013 Actual submission date: 04-09-2013

Start date of project: 01.01.2011 Duration: 36 months

Project co-funded by the European Commission within the Seventh Framework Programme

Dissemination Level

PU Public X

PP Restricted to other programme participants (including the Commission Services)

RE Restricted to a group specified by the consortium (including the Commission Services)

CO Confidential, only for members of the consortium (including the Commission Services)

Organisation name of lead contractor for this deliverable: Lithium Balance A/S

Development of novel SOlid MAterials for high power Li polymer BATteries. Recyclability of components.

NMP3-SL-2010-266090

D3.2 – Battery management System of the cells developed (PU) Page ii/18

Revision History

Revision Date Description Issued by

1.0 05/08/2013 Creation of the First draft Karl Vestin (LB)

2.0 04/09/2013 Final revision Mayte Gil-Agustí (ITE)


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Table of Contents EXECUTIVE SUMMARY ..................................................................................................... 4

1 INTRODUCTION .......................................................................................................... 5 1.1 This Document ........................................................................................................................................ 5 1.2 Objective .................................................................................................................................................. 5 1.3 Intended/Main Audience ......................................................................................................................... 5 1.4 Glossary ................................................................................................................................................... 5

1.4.1 Abbreviations .................................................................................................................................... 5

2 GENERAL SYSTEM DESCRIPTION ........................................................................... 7 2.1 System Block Diagram ........................................................................................................................... 8

3 HARDWARE DESCRIPTION ....................................................................................... 9 3.1 Hardware Description ............................................................................................................................. 9 3.2 Electrical Specifications ....................................................................................................................... 10 3.3 Physical Specifications R01 ................................................................................................................ 11

4 FIRMWARE DESCRIPTION ...................................................................................... 12 4.1 General Firmware Description ............................................................................................................. 12

5 DIAGNOSTICS SOFTWARE ..................................................................................... 13 5.1 General Description .............................................................................................................................. 13 5.2 Graphical User Interface ...................................................................................................................... 13

5.2.1 Basic View ...................................................................................................................................... 13 5.2.2 Detailed View ................................................................................................................................. 15

6 DISPLAY INTERFACE ............................................................................................... 18 6.1 General Description .............................................................................................................................. 18


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Executive Summary A battery management system has been developed for the SOMABAT battery pack. The battery management system is designed to meet all industry best practises for managing lithium ion battery packs, including fast high-precision cell voltage and cell temperature measurements. Integration with a commercially available industrial display has been developed to facilitate efficient battery testing and to provide a good demonstration platform for dissemination activities. This version of the document is for public dissemination.


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1 Introduction 1.1 This Document This document describes the battery management system developed for the SOMABAT project.

1.2 Objective The objective of this document is to provide its reader with sufficient information to understand how the SOMABAT battery management system works and how it can be used for demonstration, testing and dissemination.

1.3 Intended/Main Audience The intended audience for this document are anyone interested in the SOMABAT battery management system.

1.4 Glossary The glossary provides the coherent terminological framework used in this SOMABAT document.

1.4.1 Abbreviations Term Meaning CAN Controller area network. Standard bus for communication in vehicles.

CMU Cell management unit, the main board of the battery management system

DLC Data length code

EEPROM Electrically Erasable Programmable Read-Only Memory. A kind of non-volatile memory.

GND Ground

GUI Graphical User Interface

HAL Hardware abstraction layer. A logical software layer

I/O Input/Output

IDE Integrated development environment. A tool for software development.

LED Light emitting diode. A small board mounted light emitter.


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MOSFET Metal Oxide Semiconductor Field Effect Transducer. A semiconductor switch.

OV Over voltage condition

PCB Printed Circuit Board

RX Receive

SOC State of Charge

SOH State of Health

SPI Serial Peripheral Interface. A bus for communication between electronic components.

TX Transmit

USB Universal Serial Bus

V[N] Cell voltage on cell number [n]


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2 General System Description

This system is intended for battery management purposes for Li-ION battery packs with up to 16 cells in series connection. The system is able to monitor the pack parameters up to a single cell precision, manage and monitor the charge and discharge of the battery pack, guarantee a safe exploitation of the battery pack under the conditions that the system (CMU, battery pack, load, charger, wiring) is configured corectly (both hardware and software wise).

In general the CMU system consists of the following elements:

• CMU PCB – the actual hardware that is connected to the battery pack and performs the measurements of the pack parameters.

• CMU Firmware – the firmware that is running on the MCU providing the functional logical operation of CMU.

• CMU Diagnostics Software - the applciation running on Windows(R) platform that provides interfacing capabilities to the CMU and displays the data aquired from CMU visualy.

• PEAK(R) CAN to USB adapter – provides a physical communication link between CMU and a PC running CMU Diagnostics Software.

• Wachendorff(R) OPUS A3 display – a display with a GUI that provides a more portable representation of the relevant monitoring data from CMU.

All the communication between the elements within the CMU system and between CMU system and some other elements outside the CMU system is provided using the CANbus.


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2.1 System Block Diagram


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3 Hardware Description 3.1 Hardware Description

The PCB is FR4, 100mm X 160mm 4 layered with internal ground and 5V planes. The PCB contains 6 MicroFit connectors and a 5 pin connector for in-circuit programmer. Furthermore the PCB has four 4.5mm mounting holes in corners and 4 mounting holes for heatsing for the balancing resistors. The diagram bellow shows the general overview of the CMU functional blocks. It is followed by the description of each block.


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3.2 Electrical Specifications

Parameter Optimal MIN…MAX Supply voltage 12 V 9...16 VDC

Power consumption 185 mA @ 5 VDC

Storage temperature 20 -40 to +120

Operating temperature 20 -40 to +85

Voltage drop over shunt - -150mV to +150mV

Cell measuring voltage - 0V to 4.8V


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3.3 Physical Specifications R01


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4 Firmware Description 4.1 General Firmware Description The firmware for the CMU is written in C programming language using MPLAB IDE. The firmware is structured in several libraries depending on the functionality. The libraries interact to each other with function calls. The execution of main functionality is provided by the main loop. The following diagram shows the general concept of the design.

The diagram bellow shows the general structure of the firmware.

RAM Digital I/O Flash CAN transceiver

HW overvolt. protection

SPI link

EEPROM

HAL BOOTLOADER

Analog I/O

Abstraction layer

Physical layer

Firmware modules

Fault management

Application layer


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5 Diagnostics Software 5.1 General Description PC Diagnostics Software is an application written in C# language using Microsoft (R) Visual Studio 2008. It is meant for interacting with CMU via CAN bus. It’ s main purpose is to display the data graphically and to allow user to change system settings and update CMU firmware. For the communication between CMU and PC a Peak (R) PCAN-USB adapter is used. To manage the functionality of this adapter the appropriate .dll system library is used. The software is based on .NET 3.5 framework.

5.2 Graphical User Interface In general the main purpose for the user interface is to provide easy-to-read information about the system. In order to do this the design concept is to keep the user interface as simple as possible and to show only the amount of date that the user wishes to see. This is achieved by 3-step expansion:

1. Basic View 2. Detailed View 3. Detailed View with graphs

Furthermore it is possible to get a more detailed Error Pop-Up Window when clicking on the Errors window in the Status group.

5.2.1 Basic View

As it can be seen in the image above, the basic view contains the most basic and general information about the system and the pack.


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The status group provides the general information of the system. The uppermost “LED” indicator is displaying whether there are any errors present in the system.

• Green: no errors • Red: errors present

The adjacent system status indicates the general status of the system. The possible status notifications are as follows:

• Disconnected • Pre-charge • Connected • Stand-by

The four indicator “LEDs” below the status indicator shows the state of the IOs of the CMU. The states are as follows:

• Green: connected/ON • Gray: disconnected/OFF

Lastly the errors window shows what type of errors are present. If the error window is clicked, it is possible to get more detailed view of the errors. The pack data shows the general information about the pack and the cells. The following information is displayed:

• State of charge in percent • Pack voltage in volts with 0.1V precision • Highest cell voltage • Lowest cell voltage • Average cell voltage • Pack current in amperes with 0.1A precision • Highest cell temperature • Lowest cell temperature • Average cell temperature


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The connection indicates the state of the connection with the CAN bus and the data connection. If the PC is connected to CAN bus with PEAK USB to CAN adapter, then the CAN “LED” will be green and if there is a valid data being transmitted through the CAN bus, that originates from CMU then the data “LED” will also be green. The “More” button will expand the interface to the Detailed View. 5.2.2 Detailed View

When pressing the “More” button in the Basic View, it is possible to expand to the Detailed View in order to see more information about the system. Also it is possible to collapse back to Basic View by pressing “Less”. The Detailed View still keeps the basic information provided by the Basic View. The additional information provided by the Detailed View is divided into several tabs depending on the type of information showed. The tabs are as follows:


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• Extended System Information • General Settings • CAN Settings

Extended System Information provides the information about each separate cell voltages and shows if the cell management for that particular cell is enabled. It also shows the temperature for each cell and whether the particular temperature sensor is enabled. Furthermore it shows the temperature of the PCB board, which is relevant when cells are being balanced. The information in this view is updated every second. General Settings tab provides the information about the CMU settings that are in place. In the image bellow it is possible to see the view of how these settings are displayed.

As it can be seen the settings are grouped dependent of their type. They are updated when the General Settings tab is first viewed after opening the program. Since it is not


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too often that the settings are changed they do not auto-update in order to relieve the data that needs to be processed on CMU and the data flow on CAN bus in general. If the settings are changed while the Diagnostics Software application is open it is possible to press the “Refresh” button in order to get the updated settings information.


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6 Display Interface 6.1 General Description It is sometimes unnecessary and cumbersome to use the Diagnostics Software in order to obtain data from the CMU. Often it is not needed (or even not wanted) to show all the data from the Diagnostics Software. Furthermore the Diagnostics Software, as its name states, is meant for diagnostics purposes, not everyday interaction with CMU. For such purposes an externally mountable display solution is provided. The display used is Wachendorff (R) OPUS A3 family display running Lithium Balance user interface. It obtains the information from the standard status messages sent by CMU on CAN bus The display can be panel mounted in a dashboard or other surfaces or used as plug-and play hand-held diagnostics tool. It can be used by both technicians and end-customer.

Documents

D3 2 Battery Management System of the cells developed v2.0 PU · D3.2 – Battery management System of the cells developed (PU) Page 5/18 1 Introduction 1.1 This Document This document