Design of Lion-Battery Storage Management

System with Energy Feedback

Xia Kun, Xu Xinyue, Ji Nuo, Yuan Yin
School of Optical-Electrical and Computer Engineering, University of Shanghai for Science and Technology, Shanghai, China
E-mail: xiakun@usst.edu.cn

Abstract--A lion-battery storage management system with 60 V and the rated capacity of them is 100Ah.
energy feedback for LiFePO4 batteries was designed in this
paper. This system contains energy balance unit, state of
battery detection and CAN bus transmission. The MCU
STM32 controls all data acquired from batteries and the
main loop current detection. Each balance module uses
ATMage16 as core and achieves the balance purpose based
on synchronous rectification with the half bridge converter.
The experiment results show that the system has well
balanced speed and stable communication ability.

Index Terms--BMS, Lion-Battery, Energy Feedback,

CAN bus

I. INTRODUCTION Fig. 1. Battery distribution

With the renewable energy drying up constantly and
environmental pollution deteriorating, replacing
traditional fuel automobile by new energy vehicles has
become an inevitable trend in the development of the car
industry. New energy vehicles are divided into electric
vehicle (EV), hybrid electric vehicles (HEV) and fuel cell
electric vehicles (FCEV) [1][2]. Because of being not
mature and expensive cost, the fuel cell technology is still
in the exploration. HEV use fuel as the power supply
mainly and the electric power when they are in the low
speed, start, and speed up in order to improve the
combustion efficiency of fuel. It is an interim technology
when the big range charge network has not been built.
Based on the situation of China, EV should be the
development direction to promote powerfully. It has high
energy efficiency, little environmental pollution and
mature technology relatively characteristics, and will be
the new traffic tools in the near future [3].
At present, EV is still in the initial stage of
development, and the bottleneck is the batteries in the
electric car [4]. Since single battery storage cannot reach
the application requirements, more batteries would be
connected in series in practical applications [5].
Lion-battery storage management system mainly includes
four parts, preventing battery over charge or over
discharge, temperature control, battery balance, and
SOC[6]. In order to meet Lion-battery pack requirements,
a design of high efficiency and stability battery
management system includes the ability on the battery
state detection, battery balanced adjustment, charge or
discharge management and CAN communication was
approved in this paper.
Battery box is a cube with 20 Lion-batteries divided
into four groups which are set close to the edge of the
battery box. Due to the special requirements of
Lion-battery used in series, it needs to detect each of
batteries’ voltage and temperature. In this design, every
balance module installs in the side of batteries, and only
communicates with CAN bus. So it brings great
convenience to battery installation, commissioning and
replaceability.
According to the requirements of battery storage
management system, every battery module function
includes battery voltage equilibrium, temperature
detection and CAN bus communication. The core chip
STM32, supplied by a separate power, controls the main
loop current detection and receives the battery information
sent by every module, then judges the status of charge or
discharge, executes protection programs and shows
information for SOC or SOH estimation in the LCD. If
these batteries work wrong, alerts will be sent and
displayed.

II. SYSTEM STRUCTURE

A. Hardware structure design
As the structure shown in Fig. 1, the rated voltage of
Lion-battery pack, connected in series by 20 batteries, is Fig. 2. The hardware structure
 As the hardware structure shown above, every balance
module balances the batteries storage at the same time, and
sends voltages, temperatures and state information to
STM32 with CAN bus. Each of them works autonomously
as an independent current node, and this distributed design
is convenient to replacement. Every balance module uses
ATMage16 as core chip which is responsible for adjacent
battery voltage equilibrium, temperature detection and
CAN bus communication. The battery’s SOC and SOH
will be analyzed, calculated and shown in the LCD screen.
B. Balance module
Balance module aims to keep the storages of adjacent
batteries at the same level. This design uses the
Buck-Boost circuit as a bridge of battery energy two-way
transmission [7]. The principle of Buck-Boost circuit is that
the power supply will charge to the inductance first, and
then the inductance discharges to the load with the
fly-wheel diode. The rated voltage of each battery is 3.8V
and the voltage drop of fly-wheel diode is 0.4V or more.
Obviously, when the working state is large current, it will
reduce the energy transfer efficiency. In this paper,
synchronous rectifier technology is applied to Buck-Boost
circuit to improve the system efficiency. As the circuit
show in Fig. 3, based on the original Buck-Boost circuit,
the synchronous rectifier technology is realized with the
half bridge drive chip IR2103 and not any additional
MOSFET.
Fig. 3. Balance module
The negative terminal of battery B2 is looked as the
ground. Two groups of MC34063 booster module provide
two voltage output, 12V and 5V. The 12V supplies for
half bridge drive IR2103 with the 5V for the single chip.
The voltage of battery B1 is sent to the single chip input
port AD0 by the amplifier OP07-1, and the voltage of
battery B2 is sent to the input port AD1 directly. OP07-2
connects R1 in parallel to detect the direction of current.
The benchmark voltage 2.5V comes from TL431, and
amplifier OP07-2 sends the direction to the single chip
input port AD2. If the voltage of AD2 is greater than 2.5V,
the circuit is in the stage of that B1 is charging to
inductance L or inductance L is charging to B2. If the
voltage of AD2 is less than 2.5V, the circuit is in the stage
of that B2 is charging to inductance L or inductance L is
charging to B1. The current direction aims to help the
single chip controlling the synchronous rectifier
MOSFET.
The steps of work state are as follows:
If the battery’s voltage VB1 > VB2: (1) the single chip
port PD4 will generate PWM waves to control the
MOSFET Q1. When Q1 is on, inductance current is
increasing with time, and the energy will transfer from the
battery B1 to the inductance L. If the voltage of AD2 is
greater than 2.5V, the electricity will transfer by the path
B1→Q1→L; (2) after turning Q1 off, the voltage of L will
change quickly, as Q2 is in dead time, and keep diode D2
open. Meanwhile the output voltage of OP07-2 is still
more than 2.5V. The electricity will transfer by the path
L→B2→D2; (3) after the dead time, Q2 will be on and
bypass the D2, and now the electricity will transfer by the
path L→B2→Q2. Due to a very short dead time, as the
dead time of IR2103 is only 0.5 to 0.8 us, the current flows
through the diode for a very short time. When the voltage
of OP07-2 tested by the single-chip is less than 2.5V, Q2
will be turned off for preventing the countercurrent.
Similarly, when the battery’s voltage VB1 > VB2, the energy
will transfer from B2 to B1 by the L.
Essentially, the balance process of lion-battery storage
is that the battery which has more storage discharges more
energy. Each balance module node is equivalent to a
current node. In practical application, the balance of the
battery storage will work no matter the battery is in the
state of charge or discharge. Lion-battery storage balance
is a long-time state. Because of the charging
characteristics of lion-battery, the voltage difference of
two adjacent batteries is little in balance. But too much
charge current will cause the voltage of lion-battery to
float high and make two adjacent batteries be in the state
of charge in turn. According to the actual situation, it’s
more reasonable to choose Continuous Current Mode with
a lesser current.
C. Temperature detection
The battery temperature is the key for MCU to evaluate
whether the battery can be used normally. The temperature
sensor DS18B20 by DALLAS linked to the MCU with a
single bus.
D. Current detection
The BMS controls the batteries charge or discharge to
ensure it works well. At the same time, the SOC estimation
needs accurate integral of current which is constant value
feedback circuit with high precision and high speed
sampling. Hall sensor is the optimal choice to meet the
requirements of accuracy and stability.
The system uses hall current sensor LEM LT208-S7,
precision amplifier OP37 and fast AD transform chip
ADS7810 to send the main loop current to STM32.
STM32 will monitor and control the main loop IGBT work
to ensure that the power supply is safety and reliable.
As current detection shown above, STM32 is supplied
by the 7805 which gets the energy from an individually
12V power supply. At the same time, 12V power supply is
also used to produce a -12V power supply by a
Buck-Boost converter composed of MC34063 and the
±12V supply for the current sensor LT208-S7 and the
amplifier OP37.
The current sensor measures the main loop current, and
sends the voltage quantity to a low noise, high precision
operation amplifier for improving output impedance and
current. Then ADS7810 will transfer the digital quantity to
the STM32 by parallel port. This circuit can achieve the
two-way current detection and judge the battery state of
charge or discharge. If it’s in the state of charge, IGBT will
be controlled to realize constant charging with piecewise
by trigger pulses.
+12V
executed again for a while until the voltages of two
adjacent batteries are at the same level. Two adjacent
batteries can transfer the power from a higher one to
another, so the whole battery pack storage will transfer
with each other until the pack is in a unified voltage level.

LT208-S7 -12V
M
RM
+12V
ADS7810

OP37 Vin
D0～D15
CAP
-12V REF
DGND
+12V AGND1
AGND2
+5V
-12V
Buck-boost DC
7805

Fig. 4. Current detection

E. CAN bus
By the CAN bus, the battery information collection
system can transfer monomer voltage and temperature to
STM32 from the single-chip. STM32 has a CAN
controller internally, while single-chip uses controller
SJA1000 and transceiver PCA250. ATmega16 realizes the
initialization of SJA1000 and sends or receives
information. But the potential of each module is different,
so isolated the different potential by optocoupler 6N137
will realize the possibility of the communication between
of them.
The software uses PeliCAN and single filter mode.
STM32 sends remote frame to each module by the polling
methods, then receives the data frames to get the voltage
and temperature information from modules. If there is a
module which is in the state of balance, this state will be
sent to the STM32.
F. Program design
Electric vehicle’s battery will be in the work state for a
long time, so the battery pack in series needs to be
balanced relatively whether it is in charge or discharge.
The original intention of battery storage management is to
prevent the battery pack from appearing that the voltage of
battery is too high or too low and reducing the battery
pack’s life because of the barrel effect. However, in the
work state for a long time, the battery pack will charge and
discharge frequently, so it’s impossible to realize the full
absolute balance, and the balance modules also have
corresponding loss. The whole balance process will judge
whether the working voltage and temperature of two
adjacent batteries in the normal range at first, then judge
whether the voltage difference meets the requirements to
execute the balance program. The program will be
Fig. 5. Program flow diagram
G. STM32
After STM32 initialization normally, the main loop will
be connected and checked to work well first. Then it will
detect the main loop current direction to judge that the
battery is in the state of charge or discharge. If it is in the
state of charge, charging program will be executed, while
the protection program will be executed in the state of
discharge. Once a while, STM32 will send remote frames
to each battery module and receive the battery information.
If there is some battery failure or lost communication, the
main loop circuit will be cut off and displayed alarms in
the LCD screen.
III. EXPERIMENT
A. Temperature measurement
Temperature measurement is to ensure the lion-battery
in normal temperature work range. The BMS uses
DS18B20 to measure each temperature of the batteries.
Because all modules are same, the experiment selects two
groups of module to compare.
As shown in table I, the errors between each module
and thermometer temperature are in less than 0.2℃, the
relative errors between modules are in less than 0.3℃. The
experiment proves the temperature sensor measurement is
stable and reliable.
 TABLE I As shown in table II, the balance modules decrease the
TEMPERATURE MEASUREMENT
voltage difference of batteries. The modules realized the
thermometer Module 1 Module 2 function of batteries balance with the voltage differences
temperature temperature temperature in 50mv.
13.1℃ 13.1℃ 13.2℃
15.6℃ 15.4℃ 15.7℃ IV. CONCLUSION
17.9℃ 17.8℃ 17.7℃ At present, BMS is one of the core technologies of the
19.4℃ 19.3℃ 19.6℃ electric vehicle, which decides the distribution of energy
22.3℃ 22.1℃ 22.4℃ and human-computer interaction. The lion-battery storage
25.5℃ 25.6℃ 25.5℃ management system considers the characteristics of the
lion-battery pack and conforms to the requirements of the
B. Balance module measurement vehicle function. The Buck-Boost circuit based on the
The BMS focus on the balance of the batteries. The synchronous rectifier can be a very good realization of
experiment shown in Fig. 6 includes three batteries, balance between the lion-battery storage. The design of
multimeter, balance modules. Three simulation batteries lion-battery storage management system has the functions
which have voltage difference were connected in series, of information collection, constant charging with
and then connected the balance modules. At this time, piecewise and battery protection. It realizes lion-battery
record the voltages shown on the balance module when the storage intelligence and security management.
system was in work.
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Fig. 6. Equipment connection diagram 35(1), pp.28 - 35.
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