Smart BMS Hardware with Advanced Sensor Integration and Electrochemical Impedance Spectroscopy Solution

Despite significant advancements in battery management systems (BMS) across both hardware (HW) and software (SW), ensuring the safety and optimal utilization of lithium-ion batteries (LIBs) remains a challenge. A key limitation of current BMS technology is the lack of integration of chemical characteristics and sensor fusion, which are crucial for early fault detection and accurate prognostics and health management (PHM). This gap has prompted researchers and industry to incorporate these features to enhance performance and reliability. This study focuses on the hardware design and development of an advanced BMS aimed at enhancing PHM capabilities to ensure the safe and efficient operation of electric vehicles (EVs). The prototyped Smart BMS integrates state-of-the-art features, including Single-Cell Supervisors (SCS) that serve as a single-channel Cell Monitoring and Balancing (CMB) unit. The SCS also monitors Electrochemical Impedance Spectroscopy (EIS), enabling deeper insights into the internal states of individual battery cells. In addition, the system incorporates innovative multi-sensor integration by embedding temperature, strain, and force sensors within the battery module architecture. By combining these diverse sensor inputs through sensor fusion techniques, the system enhances the accuracy, robustness, and responsiveness of its diagnostic and prognostic capabilities. This approach improves the system's ability to detect early signs of degradation, thermal runaway, or mechanical stress, contributing to more reliable state estimation.