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Fifteen years of experiences

in Design & Developments

Battery Management System

Advanced battery technologies such as lithium ion, Lipo & Lifepo4 BMSrequire Battery Management Systems to ensure safety and long life performance of the battery packs. Lian Innovative lithium Battery management system is the most configurable and modular one available in the market. We started to develop custom lithium ion battery packs a long time ago. It results in in-depth knowledge of Lithium Battery Management System. The other competitor doesn’t build battery packs, so how could they know what really works? Lian Innovative has introduced a range of scalable and highly configurable battery management systems which could be used as Electric Vehicle,  Solar energy, Marine vessels, Large lithium ion battery packs, Uninterruptable Power System and Hybrid Vehicles battery management system.

Our product is designed at its core to operate in the environments with harsh electrical noise. Its performances are excellent as battery management system for electric vehicles. The advanced design allows our product to withstand very significant EMI that other BMS cannot.

Lian Innovative lithium Battery Management Systems are the outcome of eight years of experience delivering custom lithium battery management systems. It has evolved to the point where we can claim it to be one of the most reliable and effective lithium ion, Lipo, Lifepo4 battery management systems available on the market. Various models are designed for applications ranging from Large lithium battery packs grid energy storage systems, telecom power backup, Marine vessels, UAVs & UUVs and Electric Vehicle battery management system. Lian Innovative battery management systems could be used as off the shelf plug and play product, Semi-custom versions or full custom design version.

In our custom projects, we work very closely with our customer in order to deliver a custom turnkey Battery Management System solution within tight timescales and budgets. We have more than eight years of experience in designing Battery Management System for large lithium battery packs and many lessons learned from more than 12 projects worldwide.

Lithium Battery Management Systems Structure

Our BMS has three fully modular sections. Each one can be selected to be most suited to the user needs.

  1. The Central Controller Unit (CCU).
  2. The Power Controller Unit (PCU).
  3. The Cell Boards (CB).

The CCU control the functionality of the whole system and is the same in all battery management systems. It is just one model and there is no need to be changed if the battery voltage, configuration, type and other parameter changes. 

The main function of the PCU is to connect/disconnect battery from load or charger. It also measures current and voltage of the battery pack and limits the inrush current of capacitors. PCU model depends on battery pack specs. For different pack voltage and current, different PCU must be selected. Please consult us for further info. 

The CB function is to monitor the cell’s voltage and temperature and to balance it if needed. There are three different types of CB offered by Lian innovative. Selection is based on the layout of the cells and can be selected by the user to mostly suited for the application.

 

 Central Controller Unit

The CCU main function is to control Battery management system the whole system. The user interfacing, storing data, monitoring cells, activation of the contactors and all other standard tasks are done by CCU. Lian Innovative Battery Management Systems CCU is equipped with an SD card which can log all details of battery packs. It is ideal for unmanned mobile robots. After missions, the operator can be informed about each cell performance. It can also be used by Battery Management System manufacturer companies as a witness during guaranty period. We have developed algorithms that will allow the Lithium Battery Management System to identify normal aging and performance trends of cells versus those that are non-typical. Maximum life cycle and reliability will be achieved by monitoring CCU cell performance and compared with the expected ranges from cycle to cycle. In the case where an abnormal trend is identified, the CCU will take appropriate action to inform users of the situation to increase reliability and safety.

Various isolated and protected Analog and Digital IO have been provided on the system which can be setup easily by the user. Full protection is provided on central controller boards to cover user mistakes such as reverse polarity, over voltage, etc.

Central Controller Unit Specs:

  • Full battery protections
  • Balancing Lithium ion batteries (different kinds)Battery management system controller
  • In site Auto/Manual configurable
  • Cell performances log and analyzes
  • Logs and reports up to thousands hour of full details of cells and pack
  • State of Charge (SOC), State of Health (SOH),
  • Automatic %SOC calibration
  • Operational status and full alarm status indicators
  • Auto sleep function to put battery modules to sleep when not in use
  • Built in self Balancing Lithium batteries algorithms to maintain battery pack balance and optimize the charging function
  • Configurable Opto-isolated digital and analog I/O
  • Low power consumption
  • Internal alarm buzzer for audible warning
  • Communication flexibility with a variety of communication ports
  • Various ignition configurable
  • Firmware revision updates capability
  • Self-healing – abnormal conditions “clear” without intervention when condition subsides

 

 Power Control Unit

Old battery management systemsBMS Power do not include power control unit. Supplier advises the user to find some contactors, relays, fuses, shunts and other parts, connect them with some copper connectors assembling them together and run the battery. Lian Innovative discovered that most of the customers have lots of problem in power units that leads to some critical safety problem or system failure.

Lian Innovative is the first company to offer Power Control Units that integrated all parts and circuits needed to connect/disconnect the battery pack from load/charger. It fully compatible with CCU and no engineering is needed to use it in the system.PCU

In some applications, users need an Auxiliary 12/24/48 volts supply to run the PcBs and circuits. Some battery experts advise them to use another low voltage battery, that results to increase weight, costs and reduces the reliability and etc. Lian Innovative is the first company that integrated an advanced, reliable, DC-DC converter to PCU that not only supply the power of its internal circuits but also can supply users external circuits power. This advanced option makes the system designs as simple and reliable as possible.
The PCU provides the ability to differentiate in-rush currents (such as engine start) from short-circuiting currents. Direct hardware monitoring ensures a quick response to short-circuit or overcurrent conditions as witnessed by the main battery shunt. Special contactors can connect and disconnect heavy loads from battery pack safely and reliably. A current limiter is provided to be used on systems with high capacitors in parallel to the load.

Lots of options and sizes available to helps users to select the best-suited choice for their applications. It is totally cost effective, safe, time effective and fault proof solution that helps the users to integrate the battery management system easily and with less engineering.

  Power Control Unit Specs:

  • Aux power supply can be up to 750w, 48 volt
  • Handle up to 1000A 900Vdc 
  • Precise pack current measurement by Shunt sensor
  • Precise pack voltage measurement 
  • Safely and reliably connects/disconnects battery pack to load/charger
  • Inrush current limiter
  • DC fuse included
  • Reverse voltage protected
  • protection against inductive load disconnection

 

Switching Current Switching Voltage Aux Power supply voltage Aux Power supply power Inductive loading switch Dc Line Fuse Dual line Relay Capactive load switching Dimension mmxmmxmm
PCU500 500A+ 900Vdc 5/12/24/48 250/500/750 yes 750A yes yes 270x220x103
PCU200 200A 350VDC 5/12/24/48 250/500/750 yes 300A yes yes 260x190x103
PCU100 100A 350Vdc 5/12/24/48 250/500/750 yes 150A yes yes 240x190x103
PCU60 60A 350Vdc 5/12/24/48 250/500/750 yes 90A yes yes 220x170x103

 Cell Boards

Three different cell boards introduced by Lian Innovative for various applications, distributed wired, distributed wireless and integrated board. They cover all needs of different battery packs including Hybrid Vehicle, Marine vessels, Autonomous Underwater Vehicles, Large lithium battery packs, Uninterruptable Power System, EV Battery Management system, and etc. Full protection is provided on the cell monitoring boards to cover user mistakes such as reverse polarity, over voltage, etc.

 

  • InnoCab: distributed wired CB       
  • InnoLess: distributed wireless CB     
  • InnoTeg:  integrated CB    

. . .

InnoCab, Distributed Wired cell monitoring

Innocab is a distributed cell monitoring InnoCabboard which suited for large lithium battery packs with considerable distance between cells or battery packs of which the configuration or voltage may vary during the design and development.

InnoCab Battery Management System unique specs:

  • Fully configurable from 1 to 252 cells
  • large lithium battery packs for lithium ion/Lipo/Lifepo4 battery packs from 3.7Vdc to 1000Vdc
  • No engineering needs to setup and use
  • Auto sleep function to put battery modules to sleep when not in use
  • Temperature compensated voltage measurements resolution down to 1 mV with 10 mV accuracy in full temperature range
  • temperature measurement resolution down to 0.1 C and 1 C accuracy.
  • Cell balancing current up to 2A
  • Voltage and temperature of each IMG_5949cell to ensure the safety and long life
  • Highly redundancy for data cable disconnection, or one cell monitor board crash
  • Fail safe network guarantees that if one cell monitor board crashes the others can continue their job
  • Epoxy-encased cell modules resist dust and moisture
  • LED indicators on each cell

. . .

InnoLess, Distributed Wireless cell monitoring

Innocab is wireless distributed InnolessBattery Management system which suited for battery packs with a very large distance between cells, or for whom which not happy with bird nested wiring or very high voltage battery packs which electrical shock hazard concerns for the user, repairmen, and maintenance service men.

InnoLess BMS specs are as below:

  • Fully configurable from 1 to 252 cells
  • Battery Management System for lithium ion, Lifepo4 battery packs from 3.7Vdc to 1000Vdc
  • No engineering needs to setup and use
  • Voltage and temperature of each cell to ensure the safety and long life
  • Auto sleep function to put battery modules to sleep when not in use
  • Temperature compensated voltage IMG_5957measurements resolution down to 1 mV with 10 mV accuracy in full temperature range
  • temperature measurement resolution down to 0.1 C and 1 C accuracy.
  • Cell balancing current up to 2A
  • Highly redundancy for wireless connection, or one cell monitor board crash
  • Fail safe network guaranties that if one cell monitor board crashes the others can continue their job
  • Epoxy-encased cell modules resist dust and moisture
  • LED indicators on each cell

. . .

InnoTeg, Integrated cell monitoring

Innoteg is advanced integrated InnotegBattery Management System which suited for economical mass productions battery packs that price is the main parameter.

 

InnoTeg unique specs:

  • Fully configurable from 5 to 252 cells
  • Battery Management System for lithium ion, Lifepo4 battery packs from 20Vdc to 1000Vdc
  • Voltage of each cell and temperature of each 14 cells to ensure the safety and long life
  • Auto sleep function to put battery modules to sleep when not in use
  • Temperature compensated voltage measurements resolution down to 1 mV with 10 mV accuracy in full temperature range
  • Temperature measurement resolution down to 0.1 C and 1 C accuracy.
  • Cell balancing current up to 0.5A