Customers who use products or applications powered by lithium batteries are concerning safety. As a professional custom battery pack designer and manufacturer, CM Batteries is committed to providing the most reliable battery pack. However, the Battery Management System (BMS) is the brain of lithium battery packs. what is the best battery management system？
We suggest each li-ion battery pack should be equipped with one battery management system. The BMS would monitor individual cells with overcharging, over-discharging, and overheating protection. Besides, the smart BMS provides cell balance and SOH function.
We’ll explore how to choose a custom BMS or off-the-shelf BMS.
Different Battery Management System Solutions Comparison
A comparison between off-the-shelf Battery Management Systems (standard BMS) and custom Battery Management Systems(custom BMS)
| Feature | Off-the-Shelf Battery Management System (Standard BMS) | Custom Battery Management System (Custom BMS) |
| Custom | Standard solution | Tailored BMS to your needs |
| Functions | standard protection function | SOC, SOH, sleep mode and double protection function |
| Dimension | Bigger size | Smaller size |
| Cost | Lower cost | Higher cost |
| Development time | Reliability | Zero-day |
| SOC, SOH, sleep mode, and double protection function | Basic protection | More smart and safe |
Advantages of Custom Battery Management Systems
- The custom battery management system is designed with a compact size which makes the dimension of the complete battery pack smaller.
- More functions to protect the battery pack and custom the functions according to your needs.
Advantages of Off-the-Shelf Battery Management Systems
- The standard battery management system with lower cost.
- The technology of off-the-shelf battery management systems is more mature and stable.
What is the best battery management system? If you want to make your battery pack solution more reliable, one professional battery pack manufacturer who has rich knowledge and experience on li-ion cells, BMS, and battery pack assembly will support your business success.
Off-the-Shelf BMS Cell Configurations Limitations
Most off-the-shelf BMS are tailored for specific applications of electric vehicles, or grid-tied and off-grid battery systems. These systems might be limited to working with certain battery chemistries. For example, some off-the-shelf BMS are designed exclusively for lithium-ion chemistries, while others can handle both lithium-ion and lead-acid battery packs. In addition, off-the-shelf models may only be suitable for specific lithium batteries, such as 3.2V LiFePO4 batteries or 3.6V LiNiMnCoO2 batteries.
Cell configurations play a crucial role in the compatibility and efficiency of the BMS. The format, size, and array of the batteries must align with the capabilities of the BMS. The common cell formats are as below:
- Large prismatic packs,made of 3.2V 50Ah,100Ah,280A LiFePO4 prismatic cells
- Small cylindrical packs, made of 3.2V 18650 26650,32700 cylindrical lifepo4 cells
- Large cylindrical packs, made of 33140 lifepo4 cells
- Pouches
The number of batteries in a pack can vary significantly, and off-the-shelf BMS may support anywhere from 2 to 11,000 cells, and 1 to 60 banks in series or parallel configurations. They might also monitor battery arrays ranging from 2 to 60 batteries in series or parallel.
However, the standard solutions also have limitations. At CM Batteries, we offer custom BMS solutions that provide greater flexibility and control. We can design and manufacture a BMS that precisely fits your battery pack’s configuration and application needs.
Standard Battery Management Systems Feature Limitations
As a dedicated custom battery pack designer and manufacturer, we have realized the challenges of off-the-shelf battery management systems. The BMS manufacturers strive to meet the diverse applications and industries and tailor to specific consumer needs. However, this approach inevitably leads to feature limitations without the desired functions.
Tailored Solutions for Unique Needs
Both custom and off-the-shelf battery management systems prioritize essential features such as battery cell protection, and charge/discharge monitoring. The off-the-shelf systems typically provide these core functionalities. However custom battery management systems offer the advantages of additional tailored features that enhance performance and longevity. The extra functions are included:
- Cell balancing
- Charge control
- State of Health (SOH) readings
- State of Charge (SOC) readings
- Logbook function
Choosing a custom battery management system from CM Batteries allows you to go beyond standard offerings. We can design and incorporate features specific to your application’s requirements, ensuring seamless integration and optimal performance. Whether you need advanced monitoring capabilities or specific functionalities like detailed SOH and SOC readings, our team is committed to delivering solutions that meet your exact specifications.
Data Packages and BOM: Custom Solutions vs. Off-the-Shelf Options
At CM Batteries, we prioritize transparency and comprehensive technology support for our customers. One professional custom battery pack manufacturer and custom BMS designer offers integrated solutions that include both the battery pack and the BMS system. This comprehensive package includes a full data package, Gerber data, schematics, and a bill of materials (BOM). These detailed resources empower our customers to fully understand the functions, features, materials, and component layout within the BMS system when applied to their specific applications. Off-the-shelf battery management system manufacturers will not go into such information about their goods’ manufacturing processes.
The custom BMS designer will provide a technical instruction about how to set up, install, and test the battery management system with the battery pack, but will also supply basic and detailed specifications for the electrical and mechanical features of the components.
BMS Testing of Custom Solutions vs. Off-the-Shelf Options
Off-the-Shelf BMS Testing
Off-the-shelf battery management systems undergo design testing based on specific cell configurations, battery sizes, and formats advertised to customers. While manufacturers conduct initial testing, the end customer is responsible for ensuring proper functionality post-installation. This includes verifying that the BMS effectively controls charging and discharging and monitoring initial cycles to confirm optimal operation.
Not all off-the-shelf BMS feature programmed software, some utilize analog technologies with fault detection capabilities. However, advancements are introducing more digital systems with programmable software, featuring GUI interfaces, State of Charge (SOC) displays, dashboard gauges, and status indicators. Manufacturers may seek independent testing from organizations like Underwriters Laboratories (UL) to validate performance and safety.
Custom BMS Testing
Custom BMS should be verified with the battery management systems many times before mass production. The customer and manufacturer should make their needs very clear and work closely. A complete BMS development also includes PCB assembly and testing, which will take a lot of time.
Technical Support and Maintenance
Custom BMS solutions typically come with dedicated, specialized technical support. Manufacturers offer in-depth knowledge and tailored assistance. Off-the-shelf BMS systems provide standardized technical support, which may lack the depth of understanding needed for complex or unique applications.
Regular updates and maintenance will modify the reliability and performance. Off-the-shelf BMS systems may require more frequent maintenance and updates to address evolving standards or operational requirements.
Choosing the Right Solution
The decision between off-the-shelf and custom BMS hinges on your project’s unique demands and long-term objectives. Off-the-shelf solutions offer quick development and standard quality but may struggle to adapt to future innovations. On the other hand, custom BMS solutions empower you with flexibility, scalability, and tailored support, ensuring optimal performance and alignment with evolving technologies.
At CM Batteries, we specialize in delivering custom battery pack solutions that prioritize innovation, reliability, and customer satisfaction. Whether you require precise integration with new battery technologies or scalability for expanding operations, our team is dedicated to crafting solutions that exceed expectations.
