GETTING THE MOST OUT OF AN ELECTRIC VEHICLE BATTERY

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Getting the Most Out of an Electric Vehicle Battery
Mahmoud Ismail (ATV SYS)
17.08.2022

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Copyright © Infineon Technologies AG 2022. All rights reserved.
2022-08-17
Your Speaker Today
Mahmoud Ismail Global Application Director – Automotive Energy Management Systems
Fuel Cell
High Voltage Energy Availability
High Voltage Thermal Management
Electric Compressors
PTC Heaters
Battery Management Systems
High Voltage BMS
48V BMS
12V BMS

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2022-08-17
Infineon at a glance
Financials
Business segments revenue2
Employees1
EMEA
20,360
50,280 employees worldwide
Americas
5,360
Asia Pacific
24,560
56 R&D and
20 manufacturing locations1
For further information Infineon Annual Report 2021
43%
14%
14%
29%
Industrial Power Control (IPC)
Connected Secure
Systems (CSS)
Power & Sensor
Systems (PSS)
Automotive
(ATV) # 1
Automotive
Strategy Analytics, Mar 2022
# 1
Power
Omdia, Sep 2021
Microcontroller
# 4Omdia, Mar 2022
Leading player
Focus
1 as of 30 September 2021 2 2021 Fiscal year (as of 30 September 2021
FY17 FY18 FY19 FY20 FY21
7,063 7,599 8,029 8,567
17.1% 17.8%
16.4%
13.7%
18.7%
1,208 1,353 1,319 1,170 2,072
11,060
Revenue Segment result Segment result margin
Digitalization
› Productivity
› Comfort
› New use cases
Decarbonization
› CO2 saving
› Energy efficiency
› Sustainability

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2022-08-17
What is BMS and Why Every Battery Needs One?
1 5
Challenges Building High Voltage BMS
2 9
Speeding up Time and Reducing Cost of BMS Developement
3 25
Reference to Learn More
4 29
Table of contents

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1 5
2 9
3 25
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Table of contents

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Key functionalities of a BMS
What is BMS? and Why Every Battery Needs It?
› Every battery is
made of set of
cells
› Each cell has a
complex states
(SoC, SoH,
SoP..)
LFP
LMO
LNMCO
LTO
20 80 100
60
40
2.0
2.5
3.0
3.5
4.0
4.5
Open
Current
Voltage
(V)
State of Charge (%)
› Battery cells are always on (Cell nominal
voltage > 3V)
› Cells in
series are
prone to mis-
balancement
Initial State
Full Discharge
Full Charge
› The cells are located in harsh environments
Calculate the battery states
Protect the battery & the load
Optimize the battery performance

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What is BMS? and Why Every Battery Needs It?
Battery Cells BMS
Battery Pack

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Infineon Offers BMS Solutions for various voltage classes:
12V, 24V, 48V, 72V and High Voltage (400/800 V) Systems
12-24V Batteries
› Start stop, power
distribution
Functions
› Lead acid
› Lithium Ion
Chemistries
ASIL B (ASIL C for
thermal runaway)
Safety Level
High Voltage Batteries
› Start stop,
regenerative
breaking, torque
boost, electric drive
Functions
ASIL D
Safety Level
› BEV
› PHEV
› FHEV
› FCEV
Vehicles
48-72V Batteries
Functions
› Start stop,
regenerative breaking,
torque boost, electric
drive
Vehicles
Safety Level
› E2/3W
› MHEV
SIL-ASIL B
ASIL B-D

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2 9
3 25
4 29
Table of contents

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Different Types of HV BMS
BMS
400V Systems
Supporting up to
ASIL-D system level
safety on many
battery platforms
such as:
• 400V
• 800V
• Cell to module
• Cell to pack
• Interchangeable
400/800V
• Swappable
batteries
• Wireless and
wired BMSs
• High availability
high voltage
batteries
• Etc.
BMS
400V
400/800V
Interchangeable Systems
400V
BMS
800V
Systems
BMS
BMS
Swappable
Systems
Wireless
Systems
BMS

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2022-08-17
...
CSC#1
CYW8982x
CSC#n
CYW8982x
CSC#n
CSC#1
Infineon one stop shop for high voltage BMS products
HV BMS Product Portfolio (400V/800V)
Wireless BMS Solutions
Wireless
device
Software
component
Standard
products
AURIXTM BMS portfolio
BMU
V/I module
OPTIREGTM
TLF35585
AURIXTM
TC37x
PSoCTM 4
HVPA
To shunt
Isolation
monitoring
AUIR2085
Isolated
supply
Switch Relay
Cooling
System
Switch Relay
CAN TR
TLE9350 MCAL
CYW8982x
CYW8982x
CSC = Cell Supervision Circuit; can contain one or more BMS ICs
Excelon™
FRAM
Wired BMS Solutions
Isolation
- + - + - + - + - + - + - + - +
HV- HV+
BMU
OPTIREGTM
TLF35585
AURIXTM 2G
TC37x
Complex Device
Driver (CDD)
BMS TR
TLE9015DQU
...
Isolation
CAN TR
TLE9250
optional
MCAL
V/I module
PSoCTM 4
HVPA
To shunt
Isolation
monitoring
AUIR2085
Isolated
supply
Iso-UART
Iso UART
Switch Relay
Switch Relay
Switch Relay
Switch Relay
Cooling
System
- + - + - + - + - + - + - + - +
HV- HV+
Pressure
Sensor
KP2xx
PROFETTM
HITFETTM
TETRIS4
TLE9104
TETRIS4
TLE9104
PROFETTM
HITFETTM
• TLE9012DQU: 12 channel BMS
cell balancing & sensing IC
• PSoCTM HVPA: Accurate sensor
w/ARM M0+ core
Wired BMS specific products
• TLE9015DQU: Dual channel
UART to iso-UART transceiver
Wireless BMS specific products
• CYW89820: Bluetooth SoC
Standard products
• AURIXTM: TC3xxx Safety
Microcontroller
• OPTIREGTM: TLF35584/5 Safety
PMIC
• AUIR2085: Isolated Pre-Regulator
• TLE9350: CAN Transceiver
• KP2xx: Pressure sensor
• TLE9104SH: Quadswitch
• PROFETTM: High-side smart switch
• HITFETTM: Low-side smart switch
• ExcelonTM: FRAM non-volatile RAM
BMS Products
TLE9012DQU
TLE9012DQU
TLE9012DQU
TLE9012DQU TLE9012DQU TLE9012DQU
BMS specific products
Complex Device
Driver (CDD)
Pressure
Sensor
KP2xx

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How much can BMS effect the performance of a battery?
70 kWh battery @ $100/kWh
5% EoL SoH error is not untypical
For every 1% error in SoC $70 of
the cells is wasted
$350 is battery value estimation

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Lithium Ion cells is a low cell voltage that is always on
LFP
LMO
LNMCO
LTO
20 80 100
60
40
2.0
2.5
3.0
3.5
4.0
4.5
Open
Current
Voltage
(V)
State of Charge (%)
+VBat
-VBat
• Low nominal voltage:
Vnom = 2.2 to 3.7V
• A healthy battery cell
maintains a major
portion of the nominal
voltage even at 0%
state of charge
Building a battery with higher
voltage requires stacking of the
cells

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2022-08-17
TLE9012DQU
Li-ion battery monitoring and balancing IC supporting ASIL D systems
› Balancing & monitoring for up to 12 cells in series
› Robust Infineon 90V/130nm automotive technology supports hot plugging and
enables digital features
› Dedicated 16-bit delta-sigma ADC per cell enabling synced & filtered
measurements
› Several built-in digital filtering (down to 70Hz cut-off)
› Long running ADC mode with adaptive sample times for up to ~92ms
(<10Hz cut-off) averaging.
› Secondary ADC with same filter characteristics for a synced cell voltage
plausibility as advanced End-to-End safety mechanism
› 13th DS-ADC with the same filter characteristics for synced block voltage
measurements
› Compatible with Infineon complex device driver for TC3xx
› 5 NTC channels + additionally 4 GPIOs to connect e.g. an external EEPROM
› UART & robust capacitive coupled interface for daisy chain & ring mode
communication
› Supporting up to ASIL-D BMS safety applications
› Small package (TQFP-48) & high feature integration for a
lean external BOM
Cell Management Unit
U12
G11
U11
G10
U10
U12P
G1
U1
G0
U0
GND
IFH_L
IFH_H
IFL_H
IFL_L
VDDC
VIO
VS
TMP1
TMP4
U2
Vregout(VDDA)
TMP_GND
isoUART
Interface
Low-Side
isoUART
Interface
High-Side
TMP3
TMP0
Power Management
Unit
Main regulator
Ref. A
ΔΣ ADC 16bit
Chan. #12
Sleep regulator
Main oscillator
Sleep oscillator
Power management diagnosis
P
COMP
#12
Ref. A
ΔΣ ADC 16bit
Chan. #11
P
COMP
#11
Ref. A
ΔΣ ADC 16bit
Chan. #2
P
COMP
#2
Ref. A
ΔΣ ADC 16bit
Chan. #1
P
COMP
#1
Ref. B
DAC
SAR
MUX
SAR 11bit
Ref. B
ΔΣ ADC 16bit
Block #13
Digital Control
&
Registers
ERR
Diagnosis Unit incl. Round Robin
REF. B
GNDA
VDDA
REF. A
GNDA
VDDA
GPIO0/UART_LS
GPIO1/UART_HS
UART /
GPIO
PWM0
PWM1
TMP2
Key benefits Block diagram
Click here for Datasheet and Product page

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Communicating between grounded and isolated voltage
domains
+VBat
-VBat
• High voltage
isolated domain
• 12V grounded
Domain
Battery
Control
Unit
(BCU)

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› Supports BLE connected mesh
› Robust network availability
› Superior reliability to other solutions in the market
› Very low latencies and packet error-rates
Click here for Product Information
Infineon solutions to communicate to the central BCU data from BMC
IC
Key offering
TLE9015DQU
iso UART Transceiver IC
 Isolated communication interface for
wired BMS (capacitive or inductive)
 Dual UART-to-isoUART interface to
 Support ring mode with a single device
CYW8982x
Bluetooth 5.0 & 5.4 SoC
 Support wireless BMS communication
 Bluetooth 5.0 & 5.2 compliant
 Baseband processor SoC with an
integrated 2.4 GHz transceiver
› Robust communication without
need of transformers or common mode chokes
› Bi-directional communication scheme using error
management logic
› Ring mode topology for further system availability at low
cost
Click here for Datasheet and Product page

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Lithium ion cells characteristics highly depend on the state
and condition of the battery cell
The cell characteristics are dependent on cell
states (e.g state of charge, state of health, etc.)
and cell condition (e.g. temperature, etc.)
+VBat
-VBat

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The BCU does the house keeping, calculates battery states and
communicates with the host controller
TRAVEO™ T2G
 Basic features for BMS available
 Supports up to ASIL-B
 Cost-optimized solution
Click here for Product page
AURIX™ TC3x
 ISO26262 certified from TÜV, ASIL-D
 Secure on-board communication through
symmetric & asymmetric crypto accelerators
 Integrated 8-bit standby controller with extremely
low current consumption
> 50 Mpcs shipped worldwide > 40 different applications > 200 joint projects secured at all major OEMs
OPTIREG™ PMIC
The #1 power supply solution for AURIX™ family
 ISO26262 compliant, supporting ASIL D
 Flexibility in efficiency optimization of and EMC performance
 Support high end AURIX™ 2G (TC38/39)
 Supporting tighter stand-by currents
 Easier debugging

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The cell flat state of charge curve is sensitive to battery
conditions
LFP
20 80 100
60
40
2.0
2.5
3.0
3.5
4.0
4.5
Open
Current
Voltage
(V)
State of Charge (%)
Measuring the state of
charge is very challenging
NMC @45C
NMC @25C
NMC @5C
+VBat
-VBat
One method to keep track of the
state of charge is Coulomb count,
which estimates the amount of
charges left or entered the battery
by measuring the current.
IBat

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Infineon offers two types of current sensing to calculate the or SoC of
the battery cells
Intelligent Battery Sensor (IBS) for
battery management
 High Precision Analog
 One-Chip Solution
 Functional Safety
PSoCTM 4 HV PA 144K
TLE4972
High precision Core-less current sensor for redundant
and diverse current sensor measurement
 Contact less sensing
 Overcurrent protection
 Minimal space
 Ideal for safety application
Key Benefits
 Stray field suppression through differential voltage
measurement of 2 Hall probes/cell
 No saturation, no hysteresis, high linearity
 Low dependency on temperature and lifetime
 Sensor comes in small SMD packages
Click here for product manual and Product page
Key Benefits
 High precision analog
 High Voltage Subsystem
 Functional Safety
 Integrated MCU

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The battery pack's internal air pressure must also be monitored as
early sign of thermal runaway
KP23x and KP25x BAP sensors
 Compatible with analog and digital interfaces
application specific pressure range
 High accuracy
 Robustness
 Design flexibility
 Compliant with the GTR20 Regulation Phase 1
 Reliable cell opening detection without a false
alarm
 ISO26262 Ready (for ASIL-B system) for KP25x
 Automotive qualification according to AECQ-100
Key Benefit
Deformation
Overcharging
External heat
Internal chemical
reactions lead to
self heating and
separator melting
Gas generation
Pressure build up
Cell opening
Cell outgasing
Smoke/fire
generation
Thermal Runaway challenge: prevent TR or give passengers enough time to safely leave their car

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Lithium ion cells must be operated within a defined safe
operating area
• A lithium ion battery needs to be
operated with in its safe operating area
• Constant monitoring of the
battery voltages, currents &
temperature
• Disconnecting the battery when
necessary
Safe
operating
area
Possible
operating
window with
improved
monitoring &
control
Operating
window under
which battery
fails
Cell Voltage (V)
0 1 2 3 4 5
-50
0
50
100
150
Temperature
(C)

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Infineon’s switches protect the battery by disconnecting it
 Wide range of high voltage
switches for developing solid-state
relays
 CoolMOSTM for up to 400V
 CoolSiCTM for up to 800V
High Voltage Switches High- & Low-
Side Smart Switches
 Wide range of smart switches for
driving mechanical relays
 PROFETTM for high side driving and
controlling
 HITFETTM for low side driving and
controlling
Key Benefits
 Support up to 24V mechanical relays
 Design flexibility
 Integrated protection and diagnostics features
Key Benefits
 Support up to 24V mechanical relays
 Applicable to 400 V & 800 V vehicle network
 Same constructed space as melting fuse
 Functional Safety according to ASIL-C
 Cost optimized system solution
 Selective, arcing-free switch-off in case of failure
 Flexible system integration

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Complementary technologies enabling HV eFuse & eDisconnect
power
CoolMOS™ S7A
CoolSiC™
› 10 mΩ BiC
› 800 A pulse current
› High power SMD
› Kelvin Source
We have a broad and high quality product spectrum to enable eFuse & eDisconnect
driving
› Safe operation
› High efficiency
› Lower system size &
weight
EiceDRIVER™
Gate Driver ICs - Infineon
Technologies
control
› Scalable
› Safe/ secure
› Broad connectivity
AURIX™
32-bit Microcontroller (MCU) -
Infineon Technologies
600V-800V N-Channel
Automotive MOSFET
sensing
› Magnetic sensing solution with
ultra-low insertion resistance
› Galvanic insulation
› Analog measurement w/ high
speed overcurrent detection
XENSIV™
Sensor Technology - Infineon
Technologies
eFuse
&
eDisconnect
650-1700V Silicon Carbide
MOSFET

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2 9
3 25
4 29
Table of contents

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2022-08-17
High
Voltage
Battery
Stack
R
TLE9015
DQU
TLE9012
DQU
TLE9012
DQU
Fast and easy evaluation of HV BMS with evaluation kits
TLE9012DQU
PSoC HVPA
TLE9015DQU
AURIX™ boards
with PMICs and
CAN & UART
interface
uC
AURIX
PMIC
TLF35584/5
CAN TR
TLE9250
UART
CAN
12 V
KIT_AURIX_TC397_TFT
PSoC™
HVPA

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2022-08-17
High
Voltage
Battery
Stack
R
CYW89820
TLE9012
DQU
TLE9012
DQU
Fast and easy evaluation of HV BMS with evaluation kits
TLE9012DQU
CYW89820
AURIX™ boards
with PMICs and
CAN & UART
interface
uC
AURIX
PMIC
TLF35584/5
CAN TR
TLE9250
UART
CAN
12 V
KIT_AURIX_TC397_TFT
CYW89820
CYW89820
UART
UART
PSoC HVPA
PSoC™
HVPA

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Fast and easy evaluation of HV BMS with dedicated software solutions
IFX SW offering
› Availability not yet defined
› Paid product
› Full functionality released
› Full ISO26262 compliant
› Qualified to be used in the final
customer software
› Availability not yet defined
› Complimentary offering
› Alpha release quality
› Limited functionality
› For application software development
AURIX™ TC3xx
Productive
Complex Device drivers
(CDD)
MCAL
Common IFX BMS SW
Interface
T1 and OEM application
software
Trial version of
Production SW
Production SW
AURIX™ TC3xx
Productive
Complex Device drivers
(CDD)
MCAL
Common IFX BMS SW
Interface
T1 and OEM application
software
› Available now
› Fast path for hardware evaluation
with IFX evaluation boards
› Scripting possibility for system
emulation
› Available in Q3/2021 (beta now)
› CAN interface for beta version
› GUI in definition phase for:
– COM State Machine Sequence &
DMA Link List
– Device Init Configuration
Evaluation software
AURIX™
Hyper-terminal
Software
Scripting LL driver
PC
interface SW
Windows GUI
Reference software
AURIX™ TC3xx
IFX
Reference
Complex
Device
driver
(iCDD)
BSW
(AUTOSAR
License
Required)
Application Example Software
RTE
(AUTOSAR License Required)

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2 9
3 25
4 29
Table of contents

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2022-08-17
Introductory video to BMS here
Get More on Our Webpage www.Infineon.com/atvbms
BMS whitepaper here
Infineon BMS products here

GETTING THE MOST OUT OF AN ELECTRIC VEHICLE BATTERY

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