Battery Management System (BMS) Bringup
Brought up and validated the battery management system for a new custom 140s6p 588V battery.
- Developed firmware drivers to send and receive cell temperature and voltage readings over isoSPI in C
- Constructed a test setup to simulate all 140 series cell groups using a Bloomy battery cell simulator
- Individually tested all 140 cell voltage reading and balancing capabilities, along with all 189 thermistor temperature readings before integrating with 588V battery
The Test Setup
- The BMS contains 14 boards, each measuring 10 series cells, all read over isoSPI
- A Bloomy battery simulator generates the cell voltages, and a harness I built splits each of its 10 channels 14 ways, 10 to every board, so all 14 boards run at once
- The boards were stacked and insulated with paper and foam to keep the setup in one compact shape
Bringup and Validation
Voltages, temperatures and balancing were each proven before the 588V pack was connected.
- Voltages: ran the Bloomy at different levels, read all 140 back over UART
- Temperatures: remapped 189 thermistor positions in firmware, then heated each one using a heat gun
- Balancing: enabled and disabled the balance resistor on all 140 series cell groups from the BMU
