Hi, I'm part of a team continuing the development of an electric vehicle at my university and I would like some guidance in implementing a Battery Management System for the power supply that is already in place.

There are currently twenty 3.2V 100Ah batteries (attached below if it helps) connected in series as it needs to power two 60VDC 2500W drive motors and one 60VDC 410W servo motor.

My main concerns are 1) short circuit, overcharge, and over discharge protection and 2) balanced cell charging.

My experience in circuits is more limited than my budget, so I prefer to pay more for plug and play if it means less DIYing.

 

You can buy ready made modules for 2, 3 or 4 cells, which will do the job of balancing and current limiting, you just need the correct charger for the cells.

 

This company has BMSs for such batteries:
https://www.ev-power.eu/
But if you want to do it yourself then, have a look at the MY2112 and HY2212 BMS ics.. there are also others available from that manufacturer, though you would have to adapt the circuit to cope with such very high currents.
Be very careful about buying batteries from China however, as many suppliers sell batteries with false capacities, and even second hand batteries, as new.

 

You can buy ready made modules for 2, 3 or 4 cells, which will do the job of balancing and current limiting, you just need the correct charger for the cells.

So I'd need 5 of those modules I assume. Do those 5 modules need to be connected to each other to collectively manage the 20 cells or is it fine if they independently manage 4 cells each?

 

Yes 5 needed, Each PCB has 4 cells, and you connect them in series to give your 62V .

There are sites that sell pcbs for cells upto 30 cells, here is one for 10 cells..

https://www.google.com/shopping/pro...zp7C6vAaQ,prmr:1,pid:2797998265909600779,cs:1

 

This company has BMSs for such batteries:
https://www.ev-power.eu/
But if you want to do it yourself then, have a look at the MY2112 and HY2212 BMS ics.. there are also others available from that manufacturer, though you would have to adapt the circuit to cope with such very high currents.
Be very careful about buying batteries from China however, as many suppliers sell batteries with false capacities, and even second hand batteries, as new.

Thanks! The BMS123 Smart https://www.ev-power.eu/Battery-Man...-Complete-Set-4-cells-with-Bluetooth-4-0.html looks like just the thing, but how might I adapt the circuit to cope with 60V 45A?