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Multi-Cell Lithium-Ion Battery Management System

For Electric Vehicle. Team Members Pramit Tamrakar- Electrical Engineering Jimmy Skadal- Electrical Engineering Hao Wang- Electrical Engineering Matthew Schulte- Electrical Engineering Adviser Ayman Fayed Client Adan Cervantes- Element One Systems Team-id - SdMay11-04.

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Multi-Cell Lithium-Ion Battery Management System

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  1. For Electric Vehicle • Team Members • Pramit Tamrakar- Electrical Engineering • Jimmy Skadal- Electrical Engineering • Hao Wang- Electrical Engineering • Matthew Schulte- Electrical Engineering • Adviser • Ayman Fayed • Client • Adan Cervantes- Element One Systems • Team-id- SdMay11-04 Multi-Cell Lithium-Ion Battery Management System

  2. Problem Statement • Develop an efficient and safe system for charging and monitoring of multi-cell series batteries in Electric Vehicles using AC to DC Switching Power Converters.

  3. System Specifications

  4. Functional Requirement • Li-Ion Battery Management (90 cells in series) • Constant-Current Constant-Voltage (CCCV) charging procedure • Battery Gauging • Temperature Monitoring • Overcharge Protection • Achieve 100 miles range per charge

  5. Non-Functional Requirements • Generating a 324 VDC power bus from a 120V VAC outlet • Ensuring safety

  6. Constraints and Technology considerations • Constraints: The charging process • Technology: • Three Stages Charging Technology • Pre - charge Constant Current stage • Constant Current charging stage • Constant voltage charging stage • Voltage converter • Boost converter circuit • MSP430 Microcontroller • Constraints: High voltage control • Technology: • Scaling down by a factor about 4 (90 series cells to 24 series cells)

  7. Market Survey • Commercially available switching mode power supply for electric vehicles is offered by Brusa. • The NLG5 provides a high voltage power source from a 120V or 240V wall outlet. • Cost: over $2,000 • Brusa does not have a Battery Management Systems. NLG503-light battery charger. 1.6 kW 200-540V, $2,145

  8. Risk Mitigation • Testing and Simulation: To prevent component damage and ensure proper design, the system will be modeled to test for expected results. • Lower Volt System: With the 42V – 86.4V scaled down system, the risk a shock is reduced. • Smart and Safe: By knowing how to be safe and building the system with human/component safety in mind will aid in avoiding risk. Electric Shock: The risk of electric shock is possible when working with a charging system. System Component Damage: As power is being applied and the charging system is running, the risk of overheating, voltage/current spikes, and incorrect connections are possible.

  9. Project Plan Milestones and Schedule

  10. Cost Breakdown Total: $520 Total: $2120.00

  11. System Design

  12. Functional Decomposition (Hardware)

  13. Functional Decomposition (Software)

  14. Large Scale design

  15. Small Scale Design

  16. UCC28019AEVM Boost Circuit Will supply the needed maximum 324 volts to the buck circuit for the large scale charger 350 W Power Factor Correction (PFC) boost converter 390 VDC regulated output 0.9 A of load current Advanced fault protection

  17. Buck circuit and Feedback Loop • The buck circuit will take the voltage generated by the boost buck down to cells • The negative feedback loop • Negative feedback tends to compare actual voltage with desired voltage and seeks to reduce the difference Scaled down buck circuit Value of components

  18. Battery Management System • Will use TI’s processor bq76PL536EVM-3 and Aardvark USB-SPI adaptor • EVM-3 will monitor, balance and charge 24 cells in series • Will use Aardvark to gather the packet of information and display in the PC using using Evaluation software

  19. Implementation of the bq76pl536 with 24 series cells

  20. Software Technology Platform • Use Ti’s Evaluation software to monitor the status of batteries

  21. Test Plan • Subsystem test: • Boost Converter • System DC supply • Buck Converter with MSP430 Launch Pad • All necessary voltages and currents with PWM • Battery Management System communication • USB-SPI Processing GUI (PC) • Ability to control feedback loop from MSP430 to buck • Integration Test (scaled down): • 24 cell charge/discharge • 48V-86.4V CC (up to 3A), 86.4V CV until 0.3A

  22. Prototype Implementations & Results • Coding for the MSP430 PWM output and ADC has been completed • Basic resistor divider input has been implemented to changed the PWM duty cycle • Components for the buck converter have been sourced

  23. Current Project Status

  24. Task Distribution • System Design • Buck Converter-Matt, Hao • Boost Converter-Matt, Jimmy • Battery Management System-Pramit, Matt Jimmy, Hao

  25. Plan for Next Semester • Obtain parts and evaluation module from TI • Use what we can to quickly expand the scaled down version. • Series PCB • Use single evaluation module • Implement the buck converter. • Implement communication between the evaluation module and the MSP430 • Display charging information with a pc

  26. Questions ?

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