System Solutions for Battery

Management Systems (BMS)

June 20th, 2024
Engineering Training Days
Oscar Camacho, BMS Application Marketing Manager (Americas)

restricted 1
 Battery Management System design is easy… NOT!

A.I. Cloud computing cyber security Wireless communication

Battery passport Thermal Runaway Manufacturability
Voltage measurements accuracy Battery disconnect
Virtualization
Immunity Number of cells Electrochemical modeling
Serviceability
Functional Safety Cost per channel SoC
SoH Coulomb counting Pack-Size Scalability
Battery Chemistry Pack monitoring Active balancing
HV Isolation Isolation resistance measurements
Electrochemical impedance spectroscopy (EIS)
Battery second life Hot Plugging
Regulations
2024-06-10 restricted Copyright © Infineon Technologies AG 2024. All rights reserved. 2
Table of contents

1 BMS Trends and Challenges 4

2 Solutions for High Voltage Batteries 10

3 What to expect on future BMS designs 21

4 Call to Action and Q&A 35

2024-06-10 restricted Copyright © Infineon Technologies AG 2024. All rights reserved. 3

Table of contents

1 BMS Trends and Challenges 4

2 Solutions for High Voltage Batteries 10

3 What to expect on future BMS designs 21

4 Call to Action and Q&A 35

2024-06-10 restricted Copyright © Infineon Technologies AG 2024. All rights reserved. 4

High demand for lithium-ion batteries and automotive grade
battery management systems
Lithium Ion Battery Demand Benefits of Lithium-ion chemistry

BEV Others 250 Lithium has a high gravimetric &

100%
200 volumetric power & energy
90%
80% density

Wh/kg
150
70%
i- Ion - Smaller and lighter battery
60% L packs
100
50%
- Fast charging capability
40% d
50
b Aci Cd
30% P Ni-
20% Lithium is abundant
10% 90 180 270 360 450
Wh/L
0% 100 Long life. Li-ion batteries can
% of original capacity
23
24
25
26
27
28
29
30

maintain 80% of their capacity

80
20
20
20
20
20
20
20
20

after > 4000 charging &

By 2030, 45% of all Li-ion 60 Li-ion discharging cycles

Batteries will be 40
Pb Acid
demanded by the EV 20 Lithium is environmental
friendly (Lead & Cadmium are
market * toxic heavy metals)
1000 2000 3000 4000 5000
*Infineon Technologies AG Investor Relations
Number of Cycles

2024-06-10 restricted Copyright © Infineon Technologies AG 2024. All rights reserved. 5

However, Lithium-ion cells are challenging to manage

During Charging Both charging

I e- and
e-
Cell Reaction discharging
LiMO2 + C6 → MO2 + LiC6 + Heat reactions
Li+ generate
Li+ At cathode:
LiMO2 → Li+ + MO2 + e-
heat and lead
Li+ At Anode: to aging and
C6 + Li+ + e- → LiC6 degradation
of the cell
During Discharging
I The art of
Anode Separator Cathode e- utilizing a
Cell Reaction
lithium-ion cell
MO2 + LiC6 → LiMO2 + C6 + Heat
is to
Li+ Li+ At cathode: delicately
MO2 + Li+ + e- → LiMO2
At Anode:
manage the
Li+
LiC6 → C6 + Li+ + e- charging and
discharging
the cell

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The BMS is to the battery pack what the nervous system is to
human body

The BMS to a battery pack is what

the nervous system is to the body.
It‘s sole purpose is to:

Monitor the battery cells

Battery Pack
Battery Cells BMS
Keep the battery safe

Maximize the battery

performance

2024-06-10 restricted Copyright © Infineon Technologies AG 2024. All rights reserved. 7

A BMS is mandatory to scale lithium-ion from cells to battery
packs
Thermal Charge Sensitivity to Initial
Cell Stacking Out of Spec Operation
Misbalance Misbalance Conditions

NMC @25C 150

3.7V 4.0
NMC @5C Risk of Thermal Runaway
NMC @45C

Open Circuit Voltage (V)

100
3.5 Risk of Separator Melting
LFP

Temperature (C)

Electrode Decomposition
g
kin
50

Risk of Positive
rea
Possible
3.0 Safe

Risk of Copper EI B
Operating
Window Opera

fS
400V -15 +15 With
ting

ko
0

Dissolution
Improved
% % Area

Ris
Monitoring
2.5 & Control

-50
Plating
is k of Lithium
2.0 R
0 1 2 3 4 5
20 40 60 80 100
Cell Voltage (V)
: Battery Cell : Hot Cell : Ambient Cell : Cold Cell : Full Cell : Empty Cell
State of Charge (%)

Pack voltage is achieved Stacking cells lead to Thermal misbalance Cell condition misbalance lead to Wrong battery state estimation lead
by stacking cells thermal and aging leads to charge wrong battery state estimation to operating the cells out of their safe
misbalance misbalance operating area

The battery pack is as good as the weakest cell in the pack

2024-06-10 restricted Copyright © Infineon Technologies AG 2024. All rights reserved. 8
The BMS has a direct impact on the battery cost and warranty
Capacity Estimated Battery Benefits on 1% improvements OEM Translated Benefits
Cost

Per SoC* Per SoH/ RuL**

12-24V Batteries

< 2kWh > $100 > $1 > $5 › Extended battery

warranty

48-72V Batteries
› Extended battery
warranty
5 – 15 kWh > $1000 > $10 > $50 › Extended range
› Reduced pack cost
› Second life enablement

High Voltage Batteries › Extended battery

warranty
20 – 70 kWh > $8,000 $80 $400 › Extended range
› Reduced pack cost
› Second life enablement

* SoC = State of Charge

2024-06-10 restricted Copyright © Infineon Technologies AG 2024. All rights reserved. **SoH = State of Health; RuL Remaining Usable Life 9
Table of contents

1 BMS Trends and Challenges 4

2 Solutions for High Voltage Batteries 10

3 What to expect on future BMS designs 21

4 Call to Action and Q&A 35

2024-06-10 restricted Copyright © Infineon Technologies AG 2024. All rights reserved. 10

2.1- Cell voltage measurement and
balancing

11
Battery packs are built by stacking Lithium-Ion cells that requires
accurate cell sensing and balancing

3.7V 4s-6s à 12V

Charging
12s-14s à 48V
Un-changeable
18s-22s à 72V capacity

90s-110s à 400V
Un-dischargeable capacity
180-220s à 800V
Discharging
...

: Hot Cell : Ambient Cell : Cold Cell : Full Cell : Empty Cell
: Battery Cell • The two most unbalanced cells dictate the battery
Pack voltage is achieved Stacking cells lead to Thermal misbalance usable capacity
by stacking cells thermal and aging leads to charge • Balanced cells maximize the battery pack capacity
misbalance misbalance utilization

2024-06-10 restricted Copyright © Infineon Technologies AG 2024. All rights reserved. 12

Cell sensing and balancing methods and topologies
Single Pack BMS Multi Module Pack BMS
Decouple V/I sensing Integrated V/I sensing
Optional

Daisy Chain Redundancy

TLE9012
DQU
• Typical for high voltage
applications such as 400V
UART
Isolation and 800V.
TLE9012

PSOCTM
UART/
DQU

BMS
• Isolation is necessary.

TLE9012
CAN/

DQU
• All BMS components would
SPI IsoUART
require to be distributed
IsoUART among multiple PCBs
Isolation
• For large capacity batteries
R
external small signal
MOSFETs might be

TLE9012
DQU
required for additional
• Typical for low voltage applications such as 12V, balancing current
24V, 48V and 72V
Isolation
• Isolation is not always needed Daisy Chain
• All BMS components fit on a single PCB

2024-06-10 restricted Copyright © Infineon Technologies AG 2024. All rights reserved. 13

2.2- Pack Monitoring and Current
Sensing

14
Current sensing is required for accurate State of Charge (SoC)
estimations

Battery SoC is sensitive to the initial

cell conditions IBat

• Measuring cell states

NMC @25C
4.0 based on cell voltage is
NMC @5C
NMC @45C challenging
Open Circuit Voltage (V)

3.5
LFP
• Instead, Coulomb Pack
counting can be used to Current
3.0
estimate the battery state Sensing
-15 +15
% %
2.5
• Coulomb counter requires
the main pack current
2.0
20 40 60 80 100
State of Charge (%) Isense
: Battery Cell

2024-06-10 restricted Copyright © Infineon Technologies AG 2024. All rights reserved. 15

Current sensing methods and topologies
Hybrid Hall- and Shunt-Based
Hall-Based Pack Current Sensing Shunt-Based Pack Current Sensing
Current Sensing
Busbar Busbar

TLE497x TLE497x
Option: High-side Option: high-side

PSoCTM PSoCTM
HVPA HVPA

or or PSoCTM
HVPA
TLE9100 TLE9100

Option: Low-side Option: Low-side

TLE497x TLE497x
Busbar Shunt Shunt Shunt Shunt Busbar

• Shunt could offer higher • Dual shunt offers higher end of

• Hall sensors require no extra isolation • The hybrid solution offers the best of the shunt
accuracy than hall based life accuracy and calibration
• More reliable for over current detection and hall solutions
solutions options against alloy
• Easy to mount on both high and the low side • The hybrid solution offers more reliable
• Single shunt is typical for oxidization drifts
measurement redundancy
applications up to ASIL-C • Dual shunt is typical for
• Typically used for applications up to ASIL-D
applications up to ASIL-D

2024-06-10 restricted Copyright © Infineon Technologies AG 2024. All rights reserved. 16

2.3- Isolated Communication

17
High voltage batteries must be isolated at all times from the low
voltage domain and the vehicles ground

High Voltage Domain Low Voltage Domain

12V

TLE9012
The car chassis is connected OPTIREGTM

DQU
to the low voltage domain and PMIC
„grounded“

TLE9012

Isolation
CAN

DQU
TM
AURIX
Or
TRAVEOTM

TLE9012
DQU
The high voltage battery must
be isolated at all time to

PSoCTM
Isense

HVPA
prevent hazard to humans

2024-06-10 restricted Copyright © Infineon Technologies AG 2024. All rights reserved. 18

Isolated communications and methods and topologies
Wired BMS Wireless BMS
Decoupled V/I Topology Daisy-Chain V/I Topology Gateway Topology
Optional Optional

Daisy Chain Redundancy

Daisy Chain Redundancy

CYW8982x
TLE9012

TLE9012

TLE9012

TLE9012
DQU

DQU

DQU

DQU
Isolation Isolation Isolation

CYW8982x
TLE9012

TLE9012

TLE9012

TLE9012
DQU

DQU

DQU

DQU
Isolation Isolation

CYW8982x
TLE9015 AURIXTM TLE9015 AURIXTM AURIXTM AURIXTM
Isolation Or Isolation Or Isolation Or Or
DQU TRAVEOTM DQU TRAVEOTM TRAVEOTM TRAVEOTM

CYW8982x
TLE9012

TLE9012

TLE9012

TLE9012
Daisy Chain
DQU

DQU

DQU

DQU
Isolation

Isolation Isolation Isolation

CYW8982x
PSoCTM

PSoCTM

PSoCTM

PSoCTM
HVPA

HVPA

HVPA

HVPA
Isense

Isense

Isense

Isense
IsoFACETM IsoFACETM

Daisy Chain

2024-06-10 restricted Copyright © Infineon Technologies AG 2024. All rights reserved. 19

Isolated communications and methods and topologies
Wired BMS Wireless BMS
Decoupled V/I Topology Daisy Chain V/I Topology Gateway Topology
Optional Optional

Daisy Chain Redundancy

Daisy Chain Redundancy

CYW8982x
TLE9012

TLE9012

TLE9012

TLE9012
DQU

DQU

DQU

DQU
Isolation Isolation Isolation

CYW8982x
TLE9012

TLE9012

TLE9012

TLE9012
DQU

DQU

DQU

DQU
Classical topology
Isolation Frequently appearing
Isolation in new Future topologies Advantages:

CYW8982x
Advantages: AURIX
RFQs AURIX
Advantages: AURIX
• Increased power and AURIX
TLE9015 TM
TLE9015 TM TM TM

Isolation Isolation Isolation

• OEMs can source DQU theTRAVEO
pack
Or
TM
Advantages: DQU Or
TRAVEO TM
• Optimized BoM Or
TRAVEO TM
energy density of cell-to-Or
TRAVEO TM

monitor in dependently • Synchronous V/I • Enables X-in-1 module type of packs

CYW8982x
TLE9012

TLE9012

TLE9012

TLE9012
Daisy Chain
DQU

DQU

DQU

DQU
Isolation
from the CSCs measurement architectures • Increased production
Disadvantages: • Enables EIS light Disadvantages: automation and reduced
Isolation Isolation
• Asynchronous V/I • Optimized
Isolation BoM • OEM dependency on production cost

CYW8982x
measurement Disadvantages: single source for V & Disadvantages:
PSoCTM

PSoCTM

PSoCTM

PSoCTM
HVPA

HVPA

HVPA

HVPA
Isense

Isense

Isense

Isense
• Less optimized BoM
IsoFACETM
• OEM dependency on I measurements and
IsoFACETM
• More expensive BoM
single source for V & I gateway devices • Development complexities
Daisy Chain
measurements
2024-06-10 restricted Copyright © Infineon Technologies AG 2024. All rights reserved. 20
Table of contents

1 BMS Trends and Challenges 4

2 Solutions for High Voltage Batteries 10

3 What to expect on future BMS designs 21

4 Call to Action and Q&A 35

2024-06-10 restricted Copyright © Infineon Technologies AG 2024. All rights reserved. 21

3.1 – EV Safety and Thermal
Runaway

22
EV Safety regulations across the globe

‒ From NHTSA FNVSS 305:

‒ REESS Requirements Applicable to All Vehicles.

‒ This section of the NPRM addresses REESS safety performance requirements during normal vehicle operation.
• Overcharge
• Over-Discharge
• Over Current
• Over Temperature
• Isolation Monitor
• External Fault Protection
- Charging
‒ This NPRM’s proposed requirements would protect the REESS against external fault inputs, ensure the REESS
operations are within the manufacturer-specified functional range, provide protection from thermal propagation in the
event of single-cell thermal runaway (SCTR) due to an internal short-circuit, provide a warning if there is a thermal
event within the REESS.
* REESS: Rechargeable Electrical Energy Storage System
Source:
https://www.federalregister.gov/documents/2024/04/15/2024-07646/federal-motor-vehicle-safety-standards-fmvss-no-305a-electric-powered-vehicles-
electric-powertrain.
2024-06-10 restricted Copyright © Infineon Technologies AG 2024. All rights reserved. 23
Pack monitoring is curtail for protecting the passenger, the
battery pack and the vehicle loads

The car chassis is connected

to the low voltage domain and
„grounded“ PSoCTM HVPA offers reliable pack

Zp
level monitoring, diagnostics and
critical events detections such as:
PSoCTM • Over Current Detection (OCD)
HV PA
• Isolation resistance measurement
• Arcing detection
• Relay aging

Zn
• Relay armature control
The high voltage battery must
And more..
be isolated at all time to Isense
prevent hazard to humans
: Battery Cell

2024-06-10 restricted Copyright © Infineon Technologies AG 2024. All rights reserved. 24

Early thermal runaway detection is crucial to warn and protect the
passengers

cell voltage cell temperature

critical temperature
venting start
Optional Internal failure

Daisy Chain Redundancy

TLE9012
DQU

Cell Monitoring ICs

Isolation
TLE9012

concentration
DQU

Gas
AURIXTM
TLE9015
Isolation Or
DQU
TRAVEOTM Ambient Sensing

Gas pressure
TLE9012
DQU

Pressure
Sensor

Isolation
Gas Sensor
PSoCTM

Impedance
HVPA

Electrochemical Impedance
Isense

Spectroscopy (EIS)

Daisy Chain

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EIS principles
Excitation and measurement Signal processing Computing data

fexcitation

mid Hz range
higher Hz range

Lower Hz range
Current
t
t0 f
Q SoH
if=exc

structure
U0 110011….1110011 sin(fexc)

Input
measurement CELL ΔΣ ADC
Cell cos(fexc) Temp SoC
window
voltage
response I 0 R0 Re{Z} [Ω]
Power

-Im{Z} [Ω]
t0 t *depending on cell chemistry, structure,
use case, etc.

‒ Continuously monitoring the cell ‒ Applying trigonometry determination

Voltage and ccurrent response to a of magnitude and phase: ‒ Look for variability and deviations
known stimulus. ‒ Z= 𝐼 ! + 𝑄 ! to original cell impedance
‒ ADC bitstream is used for on-chip " characteristics.
‒ f=arctan(#)
processing

2024-06-10 restricted Copyright © Infineon Technologies AG 2024. All rights reserved. 26

Thermal runaway methods and topologies
Voltage & Temperature
Ambient Pressure Sensing Electro Chemical Impedance Spectroscopy Sensing
Sensing
Multi-cell EIS „light“ Single-cell advanced EIS

Option 1 Optional Optional

V, T

Daisy Chain Redundancy

Daisy Chain Redundancy

TLE9012

TLE9012

TLE9012

TLE9010
Pressure
DQU

DQU

DQU

EP
V, T Sensor

Isolation Isolation

Option 2 TLE9015
AURIXTM
TLE9015
AURIXTM
Or Or
DQU DQU
TRAVEOTM TRAVEOTM

V, T Pressure AURIXTM
TLE9012

TLE9012

TLE9010
Or
Sensor
DQU

DQU
TRAVEOTM

EP
V, T
Isolation Isolation
Option 3
PSoCTM

PSoCTM

PSoCTM
HVPA

HVPA

HVPA
Pressure
Isense

Isense

Isense

Isense
Sensor

Daisy Chain Daisy Chain

2024-06-10 restricted Copyright © Infineon Technologies AG 2024. All rights reserved. 27

3.2 - Edge vs. Cloud computing

28
 The battery controlling units logs the battery data, calculates the
battery states, and make the battery protection decisions

Cloud Level Computation

Software Battery States (SoX)
Partners
Disconnect Application Computational
12V Power
Driver
Level Software
High
TLE9012

SoX
DQU

Digital Twins
OptiregTM Communication
Isolation Charging

Vehicle Level Computation

Control Hybrid Models
TLE9012

AURIXTM Data Logging

DQU

Etc.
Isolation
TLE9015 Or Machine Learning
DQU
TRAVEOTM Middleware Models
CDDs
TLE9012
DQU

Application Level Software

Complex Device Driver (CDD) Signal Handling

Kalman Filters
Isolation MCAL
Etc.
Electro Chemical
Low Level Models
PSoCTM
Isense

HVPA

Drivers
Disconnect
Driver MCAL LLDs
Look up tables
Low

2024-06-10 restricted Copyright © Infineon Technologies AG 2024. All rights reserved. 29

AURIXTM TC4x Parallel Processing Unit (PPU): a scalable SIMD
Vector DSP & scalar core with a dedicated SW-tool-chain

SW-Ecosystem
PPU
Compiler

32b 128b~256b
Scalar Vector DSP Auto code
generation
TriCore I$ Vector Memory (32KB-128KB) including library
TriCore D$
TriCore
1.8
1.8
1.8 Cluster Components
Streaming Transfer Cluster Shared Memory
Unit (STU) (CSM) – 64KB-256KB MLI xNN
library SDK

› Execution 3x faster than competitor solutions, enabling Neural network based algorithms and
High-speed-control implementations
› Unique SW Ecosystem: Model-based development, connected with latest Machine-learning-tools like Tensor-
flow is enabling easy usage and fast time-to market

2024-06-10 restricted Copyright © Infineon Technologies AG 2024. All rights reserved. 30

3.3 - Battery Disconnect

31
Battery disconnect takes care of connecting and disconnecting
the battery safely
battery pack connected battery pack disconnected
high-side pre-charge path
Turn on mode high-side pre-charge path

Driving mode

Charging mode
high-side low-ohmic path high-side low-ohmic path

Cells operated outside their Safe

Operating Zone (e.g. Over charge,
Over Temperature)
Disconnect Disconnect
Driver Over Current and Short Circuits Driver

Isolation Failure

Crash

low-side low-ohmic path Parking Mode low-side low-ohmic path

2024-06-10 restricted Copyright © Infineon Technologies AG 2024. All rights reserved. 32

Mechanical disconnect driving methods and topologies

Common High Common Low Decoupled Topology

HITFETTM PROFETTM PROFETTM HITFETTM

HITFETTM PROFETTM HITFETTM PROFETTM HITFETTM

PROFETTM

HITFETTM PROFETTM PROFETTM HITFETTM

• Cost efficient way to manage mechanical disconnects • Cost efficient way to manage mechanical • Decoupled topologies avoid common failure
in a junction box disconnects in a junction box modes
• Most common topology in high voltage battery • Less common topology in high voltage battery • Less common and more expensive
junction boxes junction boxes

2024-06-10 restricted Copyright © Infineon Technologies AG 2024. All rights reserved. 33

Solid state disconnect driving methods and topologies
High Voltage State High Hybrid Solid- High Side Solid High Voltage State High Voltage State
Disconnection Mechanical Disconnection State Disconnection Disconnection Disconnection

Gate Driver Gate Driver Gate Driver Gate Driver

eDisconnect Driver eDisconnect Driver eDisconnect Driver

PROFETTM HITFETTM

eDisconnect Driver

Gate Driver
eDisconnect Driver

Gate Driver
PROFETTM HITFETTM PROFETTM HITFETTM

• Expensive disconnection • Solid state pre-charge emerging • Typical for low voltage • Typical for cheap low • Less common topology
method • Solid state pre-charge can protect BMSs voltage BMSs due to higher cost
• Typical when paralleling for mechanical relay from arching • Maintains the common • Risks of ground bypass • Advanced disconnection
large capacity packs • Solid state pre-charge doesn't ground via housing or features
• Emerging for higher ADAS require large pre-charge passives communication for
applications example

2024-06-10 restricted Copyright © Infineon Technologies AG 2024. All rights reserved. 34

Table of contents

1 BMS Trends and Challenges 4

2 Solutions for High Voltage Batteries 10

3 What to expect on future BMS designs 21

4 Call to Action and Q&A 35

2024-06-10 restricted Copyright © Infineon Technologies AG 2024. All rights reserved. 35

Check the automotive BMS application page for more details on
product datasheet, application notes, and more

Datasheets, documentation, evaluation Check our pages:

boards, Trainings, videos and much more

www.infineon.com/atvbms

Additional resources when you create

an account at myinfineon.com

2024-06-10 restricted Copyright © Infineon Technologies AG 2024. All rights reserved. 36

Q&A

37
38