Regulatory Push: How Standards Are Shaping BMS Development for Automotive Use

January 13, 2025. By News Bureau

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articles

BMS Development

Global EV outlook 2024

Battery

Battery charging operations

EV batteries

Automotive

Battery Management Systems

Energy storage system

EInfochips

Dhaval Bhagora

According to the latest IEA report on the Global EV outlook 2024, global battery demand observed the highest growth in 2023, amounting to more than 750 GWh in 2023, up 40% relative to 2022 where Electric cars contributed to ~95% of this growth. EV batteries are very critical & expensive components and account for up to 30-40% of an EV's overall cost. Hence it presents an unprecedented emphasis on the requirement of having an intelligent battery management system (BMS) to ensure safety & efficiency in high-voltage battery charging operations.

In the absence of a BMS, the battery pack would become vulnerable to damage, potentially leading to a reduced lifespan, safety hazards like overheating or fire, and significantly impaired performance due to uncontrolled charging and discharging of individual cells within the battery pack.

Before we go into the details of the functions of BMS and its role in protecting batteries, let’s look at the key some of the key safety considerations for battery operations.

According to UN Regulation No. 100 Rev.3 Part II, all EVs on road (category M and N) must comply with the safety requirements outlined below with respect to Rechargeable Electrical Energy Storage Systems (REESS) where BMS and Battery Pack are the two main components of the REESS.

Vibration Test
Thermal Shock and Cycling Test
Mechanical Shock & Integrity
Fire Resistance
External Short Circuit Protection
Overcharge Protection
Over-Discharge Protection
Over-Temperature Protection
Over-Current Protection
Thermal Runaway, Propagation

In this scenario, the role of BMS becomes crucial for monitoring, managing, and protecting the battery pack in an electric vehicle and ensuring that the cells within the battery operate within safe limits, optimize performance, and provide real-time data for the vehicle’s control systems.

Key functions of an Automotive Battery Management System:

Cell Balancing:
BMS actively monitors the charge of each cell within the battery pack, preventing some cells from being overcharged or over-discharged to maximize battery lifespan

Over-current protection:
BMS can detect and prevent excessive current draw, protecting the battery from damage caused by high-load conditions

Temperature monitoring:
By monitoring battery temperature, the BMS prevents overheating or extreme cold, both of which can degrade battery performance and safety.

State of Charge (SOC) estimation:
The BMS calculates the remaining charge in the battery pack, providing accurate information to the vehicle's system for optimal range management.

Fault detection:
A BMS can identify potential faults within the battery pack, allowing for early intervention and preventing further damage.

Secure Communication:
Battery management unit with the support of secure boot & secure firmware upgrade ensures all battery parameters are securely communicated to EMS or cloud platform.

Key Standards Influencing BMS Development
Standards provide a structured framework for BMS design, ensuring consistency, reliability, and safety across the automotive industry. Here are some of the key standards:

1. ISO26262: Functional Safety Standard for Automotive Applications
ISO 26262 governs the functional safety of electrical and electronic systems in vehicles. As the backbone of automotive safety standards, it outlines methodologies to manage risks associated with system failures. For BMS, ISO26262 mandates:

Risk assessments based on Automotive Safety Integrity Levels (ASIL).
Implementation of safety mechanisms to prevent hazardous events, such as battery thermal runaway.
Rigorous testing and validation processes.

Complying with ISO 26262 ensures that a BMS can handle failures without endangering vehicle occupants or the environment.

2. ISO 15118: Vehicle-to-Grid Communication Interface
As EV adoption grows, interoperability between the vehicle and charging infrastructure becomes crucial. ISO15118 establishes standards for vehicle-to-grid (V2G) communication, enabling seamless integration between the BMS and external charging networks. This standard influences BMS development by:

Ensuring compatibility with various charging systems
Supporting advanced features like bidirectional charging
Facilitating secure data exchange for energy management

3. UN Regulation No. 100
The UN Regulation No. 100 Rev.3 Part II is applicable to the rechargeable energy storage systems (RESS) in electric and hybrid vehicles (RESS) for safeguarding the battery under normal and extreme conditions. It covers aspects such as:

Protection against electrical shocks
Prevention of fire risks from overcharging or short circuits
Standards for mechanical durability under crash conditions

4. SAE J2464 and UL 2580: Battery Safety Testing
These standards focus on rigorous testing of batteries to validate their safety and performance. SAE J2464 outlines abuse testing methods, while UL 2580 specifies requirements for rechargeable lithium-ion batteries. Together, they influence BMS development by:

Encouraging designs that can withstand thermal, electrical, and mechanical stresses
Requiring advanced fault-detection algorithms within the BMS
Promoting the integration of robust safety features

Challenges in Adhering to Standards
While standards provide a clear roadmap, implementing them poses several challenges:

Complexity: BMS development involves integrating multiple functionalities, requiring compliance with overlapping standards.
Cost: Meeting rigorous standards demands advanced technologies and extensive testing, increasing development costs.
Rapid Evolution: Standards evolve alongside technological advancements, necessitating continuous updates to designs.

Despite these hurdles, adherence to standards is non-negotiable for manufacturers aiming to establish credibility and compete in the global market.

The Role of Collaboration and Standardization Bodies
Collaboration among automakers, suppliers, and standardization bodies is essential to streamline BMS development. Organizations like the International Organization for Standardization (ISO), Society of Automotive Engineers (SAE), and Underwriters Laboratories (UL) play pivotal roles in:

Developing and updating standards
Facilitating global harmonization to reduce regulatory fragmentation
Providing certification and compliance support

Outlook
Standards will continue to shape the future of BMS development, particularly in areas like:

Artificial Intelligence Integration: Standards will guide the use of AI in predictive analytics and fault detection.
Sustainability: Guidelines for eco-friendly battery materials and recycling will influence BMS design.
Energy Efficiency: Standards will drive innovations to enhance energy utilization and reduce losses.

Conclusion
Standards are the cornerstone of BMS development for automotive use, ensuring safety, reliability, and interoperability in an increasingly complex landscape. By adhering to these guidelines, manufacturers not only meet regulatory requirements but also gain a competitive edge in delivering high-quality, innovative solutions. As the automotive industry advances toward electrification, the role of standards will remain indispensable in shaping the future of mobility.

- Dhaval Bhagora, Senior Product Marketing Manager, eInfochips