The construction plan of an efficient 2200mah 18650 battery management system

　　Suppose you were assigned the task of designing a monitor circuit for a new and battery-based power system. What strategy would you adopt to optimize the cost and manufacturability of this design? Initial considerations will be to determine the preferred structure of the system and the location of the batteries and associated electronic components. After the basic structure is clear, the next issue that must be considered is the trade-off and coordination of the circuit topology, for example, how to optimize the communication and interconnection of the final product.

　　The external dimensions of the 2200mah 18650 battery will have a significant impact on the power system structure. Want to use a large number of small cells to fit into a complex-shaped 2200mah 18650 battery module (or 2200mah 18650 battery pack)? Or do you need to use batteries with very large dimensions, which would limit the number of batteries due to weight or cause other size constraints? This is perhaps the most variable part of the design, as new 2200mah 18650 battery designs continue to come to market and efforts continue to make 2200mah 18650 battery modules or packs more consistent with the overall product concept when integrated into a product. For example, in the case of a car design, batteries may end up dispersed in certain spaces on the vehicle that would be inefficiently utilized without the batteries.

　　Another consideration is the interconnection of test signals and/or telemetry signals between the 2200mah 18650 battery (or modular 2200mah 18650 battery pack), the 2200mah 18650 battery management system (or its subsystem), and the end application interface. In most cases, a housing can be made to integrate some data acquisition circuitry in the 2200mah 18650 battery module or 2200mah 18650 battery pack, so that if replacement is needed, important information such as production ID, calibration, usage specifications, etc. can be brought with the replaceable components. Walk. This type of information may be useful for 2200mah 18650 battery management systems (BMS) or service equipment and minimizes the number of high-voltage rated wires required in the wiring harness.

　　Next, for a given mechanical concept design, the monitoring hardware topology is determined by the precisely defined number of cells that need to be supported. In automotive applications, there are typically more than 100 2200mah 18650 battery measurement points in total, and the modularity of the system will determine how many cells a given circuit system measures. The most common situation is to separate all batteries into at least two sub-groups by safely disconnecting "service plugs". By keeping the voltage below 200V during a fault condition, this approach minimizes the risk of electrocution that service personnel may encounter. The larger 2200mah 18650 battery pack size means two separate data acquisition systems, each supporting perhaps 50 2200mah 18650 battery taps. In some cases, all electronic components are on an affordable printed circuit board, but this requires a large number of interconnects, as shown in Figure 1(a). Alternatively, the electronic components could be dispersed and more tightly integrated within the 2200mah 18650 battery module, but this would require a telemetry linking approach. To achieve reliable data integrity, remote measurement circuits built into automotive wiring harnesses must use a ruggedized protocol such as the widely used CAN bus. Although the real CAN bus interface involves several network layers, the pHY layer can be easily used to form a BMSLAN structure for efficient communication within the module. This type of distributed structure is shown in Figure 1(b). This topology allows the computing workload to be distributed among several small processors, thereby reducing the required data transfer rate and mitigating EMI issues that can arise from LAN approaches. The final BMS application interface is likely to be a CAN bus connection to a main system management processor, and will need to define (or specify at the outset) specific message transactions.

　　Other factors may also affect the physical structure and monitoring circuitry. In the case of lithium-ion batteries, cell capacity balancing is required, resulting in additional thermal management issues (heat removal), and if active balancing is required, power conversion circuitry is required. Temperature probes are often distributed throughout the module to provide a way to correlate voltage readings with state of charge, requiring some supporting circuitry and connection schemes. An often overlooked design consideration is that 2200mah 18650 battery leakage should be minimal when the product is idle or stored on shelves prior to installation. In some cases, additional control wiring is necessary.

　　Across the structures implemented above, there is a common measurement functionality building block that includes a multi-channel ADC, safety isolation barriers, and some degree of local processing. The circuit in Figure 2 shows a scalable design platform that implements data acquisition functions. In this diagram, the core component that enables the functionality is Linear Technology's LTC6803 2200mah 18650 battery pack monitor IC, along with an SpI data isolator and some optional special-purpose circuitry shown. This circuit includes the input filter and passive balancing functions, forming a complete 12-cell data acquisition solution. If desired, this type of circuitry can be simply replicated to support more 2200mah 18650 battery measurement schemes while sharing the local SpI port of the main microcontroller, which in turn provides the external CAN bus or other LAN type data link required. need.

　　A major improvement over previous generation monitoring devices, the LTC6803 supports power shutdown and/or power from a 2200mah 18650 battery pack alone. When power is removed from the V+ pin, the 2200mah 18650 battery loading drops to zero (only nA level semiconductor leakage). Operating power can be provided by the connected 2200mah 18650 battery pack voltage, or from a separate source to V+, as long as the voltage is always at least as high as the 2200mah 18650 battery pack. For simplicity, the LTC6803 can also draw power directly from the 2200mah 18650 battery pack, in which case the lowest power state (i.e. standby) will draw only 12uA. The LTM2883 data isolator is powered from the main processor through an internally isolated DC-DC converter, so the device will automatically power down along with the main processor. A very useful feature of the LTM2883 is that it can also deliver a lot of host-derived power to isolated electronic components (i.e., the 2200mah 18650 battery side). A small boost power supply function component (LT3495-1 in Figure 2) is driven in this way to independently power the LTC6803 so that the 2200mah 18650 battery provides only the ADC measurement input current (i.e. <200nA average at active conversion). This circuit has the absolute lowest parasitic 2200mah 18650 battery leakage while eliminating any 2200mah 18650 battery operating current mismatch that could otherwise progressively cause a 2200mah 18650 battery capacity imbalance.

　　Suppose you were assigned the task of designing a monitor circuit for a new and battery-based power system. What strategy would you adopt to optimize the cost and manufacturability of this design? Initial considerations will be to determine the preferred structure of the system and the location of the batteries and associated electronic components. After the basic structure is clear, the next issue that must be considered is the trade-off and coordination of the circuit topology, for example, how to optimize the communication and interconnection of the final product.

　　The external dimensions of the 2200mah 18650 battery will have a significant impact on the power system structure. Want to use a large number of small cells to fit into a complex-shaped 2200mah 18650 battery module (or 2200mah 18650 battery pack)? Or do you need to use batteries with very large dimensions, which would limit the number of batteries due to weight or cause other size constraints? This is perhaps the most variable part of the design, as new 2200mah 18650 battery designs continue to come to market and efforts continue to make 2200mah 18650 battery modules or packs more consistent with the overall product concept when integrated into a product. For example, in the case of a car design, batteries may end up dispersed in certain spaces on the vehicle that would be inefficiently utilized without the batteries.

　　Another consideration is the interconnection of test signals and/or telemetry signals between the 2200mah 18650 battery (or modular 2200mah 18650 battery pack), the 2200mah 18650 battery management system (or its subsystem), and the end application interface. In most cases, a housing can be made to integrate some data acquisition circuitry in the 2200mah 18650 battery module or 2200mah 18650 battery pack, so that if replacement is needed, important information such as production ID, calibration, usage specifications, etc. can be brought with the replaceable components. Walk. This type of information may be useful for 2200mah 18650 battery management systems (BMS) or service equipment and minimizes the number of high-voltage rated wires required in the wiring harness.

　　Next, for a given mechanical concept design, the monitoring hardware topology is determined by the precisely defined number of cells that need to be supported. In automotive applications, there are typically more than 100 2200mah 18650 battery measurement points in total, and the modularity of the system will determine how many cells a given circuit system measures. The most common situation is to separate all batteries into at least two sub-groups by safely disconnecting "service plugs". By keeping the voltage below 200V during a fault condition, this approach minimizes the risk of electrocution that service personnel may encounter. The larger 2200mah 18650 battery pack size means two separate data acquisition systems, each supporting perhaps 50 2200mah 18650 battery taps. In some cases, all electronic components are on an affordable printed circuit board, but this requires a large number of interconnects, as shown in Figure 1(a). Alternatively, the electronic components could be dispersed and more tightly integrated within the 2200mah 18650 battery module, but this would require a telemetry linking approach. To achieve reliable data integrity, remote measurement circuits built into automotive wiring harnesses must use a ruggedized protocol such as the widely used CAN bus. Although the real CAN bus interface involves several network layers, the pHY layer can be easily used to form a BMSLAN structure for efficient communication within the module. This type of distributed structure is shown in Figure 1(b). This topology allows the computing workload to be distributed among several small processors, thereby reducing the required data transfer rate and mitigating EMI issues that can arise from LAN approaches. The final BMS application interface is likely to be a CAN bus connection to a main system management processor, and will need to define (or specify at the outset) specific message transactions.

　　Other factors may also affect the physical structure and monitoring circuitry. In the case of lithium-ion batteries, cell capacity balancing is required, resulting in additional thermal management issues (heat removal), and if active balancing is required, power conversion circuitry is required. Temperature probes are often distributed throughout the module to provide a way to correlate voltage readings with state of charge, requiring some supporting circuitry and connection schemes. An often overlooked design consideration is that 2200mah 18650 battery leakage should be minimal when the product is idle or stored on shelves prior to installation. In some cases, additional control wiring is necessary.

　　Across the structures implemented above, there is a common measurement functionality building block that includes a multi-channel ADC, safety isolation barriers, and some degree of local processing. The circuit in Figure 2 shows a scalable design platform that implements data acquisition functions. In this diagram, the core component that enables the functionality is Linear Technology's LTC6803 2200mah 18650 battery pack monitor IC, along with an SpI data isolator and some optional special-purpose circuitry shown. This circuit includes the input filter and passive balancing functions, forming a complete 12-cell data acquisition solution. If desired, this type of circuitry can be simply replicated to support more 2200mah 18650 battery measurement schemes while sharing the local SpI port of the main microcontroller, which in turn provides the external CAN bus or other LAN type data link required. need.

　　A major improvement over previous generation monitoring devices, the LTC6803 supports power shutdown and/or power from a 2200mah 18650 battery pack alone. When power is removed from the V+ pin, the 2200mah 18650 battery loading drops to zero (only nA level semiconductor leakage). Operating power can be provided by the connected 2200mah 18650 battery pack voltage, or from a separate source to V+, as long as the voltage is always at least as high as the 2200mah 18650 battery pack. For simplicity, the LTC6803 can also draw power directly from the 2200mah 18650 battery pack, in which case the lowest power state (i.e. standby) will draw only 12uA. The LTM2883 data isolator is powered from the main processor through an internally isolated DC-DC converter, so the device will automatically power down along with the main processor. A very useful feature of the LTM2883 is that it can also deliver a lot of host-derived power to isolated electronic components (i.e., the 2200mah 18650 battery side). A small boost power supply function component (LT3495-1 in Figure 2) is driven in this way to independently power the LTC6803 so that the 2200mah 18650 battery provides only the ADC measurement input current (i.e. <200nA average at active conversion). This circuit has the absolute lowest parasitic 2200mah 18650 battery leakage while eliminating any 2200mah 18650 battery operating current mismatch that could otherwise progressively cause a 2200mah 18650 battery capacity imbalance.

　　A convenient feature of the LTC6803 is that it has two free ADC inputs with similar accuracy to the 2200mah 18650 battery inputs. This convenient feature allows auxiliary measurements, including temperature, calibration signal, or load current measurements, to be made with little additional circuitry. A particularly useful measurement is to use a gated resistor divider to measure the voltage across the 2200mah 18650 battery pack, as shown in Figure 2 (using a 12:1 ratio, connected to the VTEMp1 input). When the circuit is powered down, the associated FET is disconnected so that the current measurement does not unnecessarily tax the battery. Since the filtering of this port can be customized independently of the 2200mah 18650 battery input, true Nyquist sampling rates up to 200sps are possible for accurate charge current calculations. Individual cell measurements can be used to periodically provide software calibration of the voltage divider across the entire 2200mah 18650 battery pack, eliminating the need for expensive resistors. Another very useful use of the auxiliary input is to measure a very accurate calibrated power supply (such as Linear Technology's LT6655-3.3, a reference with 0.025% accuracy), in which case the software can be Inherent match to channel, corrects for all other channels. Note that thermistor temperature probes do not have to be referenced to the 2200mah 18650 battery potential, nor do these probes typically require 12-bit resolution. This type of probe is often suitable for interfacing directly with a microcontroller, leaving the auxiliary input of the high-performance LTC6803 free for more demanding functions.

　　In summary, there are many factors to consider in 2200mah 18650 battery management system circuits, especially those that determine packaging limitations. When packaging design ideas come together, it is also important to consider the structure of the electronic circuitry and information flow (e.g., connectorization and wire count) that may also have mechanical effects. Once these factors are weighed and the package design is mature, simply plug in an LTC6803 platform and you're ready for a well-established, scalable and cost-effective data acquisition solution.

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