Sensata Technologies has announced the release of their new i-BMS

Sensata Technologies has announced the release of their new i-BMS battery management system (BMS) for electrified applications up to 60V.

The new i-BMS Battery Management System from Sensata’s Lithium Balance product brand, which Sensata acquired earlier this year, is a cell chemistry agnostic, compact, integrated BMS designed for cost-optimized mass-production of applications up to 60V, such as 2- and 3-wheelers, automated guided vehicles (AGVs), and robotics.

Hot switch capabilities and parallel battery pack compatibility enable you to easily swap out drained batteries for fully charged ones. For example, while returning to base to pick up a new load, material handling vehicles, delivery vehicles, and drones’ empty batteries may be instantly switched for charged ones, providing for uninterrupted uptime. Instead of needing to recharge for several hours every evening, fully charged batteries for electric motorcycles and three-wheelers can be quickly installed in the field at battery swap stations, virtually eliminating the need to wait and charge on the road and helping to alleviate end-user concerns about charging time.

Parallel pack compatibility enables the simultaneous use of two or more battery packs. This technology enables 2- and 3-wheeler OEMs to use smaller battery modules, enhancing the battery system’s safety and serviceability. For example, if one battery cell breaks while in operation, the problem is contained to that one problematic module, which is easier to replace than the complete system, and other battery packs can provide power.

The i-BMS PCB board, measuring only 65 x 200 mm (2.6 x 7.9 in), is loaded with everything needed to control and maintain a battery system without the need of any external components, making it a practical and cost-effective Design for mass manufacturing. All important components, including a pre-charge circuit, on-board current monitoring, MOSFET power switches for battery disconnect, and a DC/DC power supply, are pre-integrated into the system. The system includes ASIL C safety-rated essential components as well as self-test capabilities for safety-critical measurement circuits.

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Sensata’s BMS software’s advanced algorithms provide accurate state-of-power (SOP) forecasts based on cell internal resistance, voltage and current limits, precise state-of-charge (SOC) calculations, and (state-of-health) SOH determined based on aging impact.

The high degree of accuracy in measuring the health of the battery enables for a more accurate battery system, allowing customers to maximize battery utilization and boost range, uptime, and vehicle performance. Furthermore, the BMS Creator configuration program enables the battery pack designer to establish a one-of-a-kind battery setup by setting application-specific BMS characteristics and safety methods, hence optimizing battery operation.

Other advanced software capabilities include temperature rate of change measurement to forecast thermal runaway, dynamical current management under high thermal circumstances, and complex parameter settings for CAN communication.

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