Rapid Development
of
Large Li-Ion Battery Packs
using
Off-the-Shelf
Battery Management Systems
9/27/09, 1,
Custom or COTS?

Custom design

you own

you control

Commercial off-theshelf (COTS)

fast

easy

little development
9/27/09, 2,
Custom or COTS?
Ownership [%]
Custom
Off-the-shelf
Cost & manuf. control [%]
Devel. cost [$k]
Devel. time [months]
Staff [people]
Learning curve [man-weeks]
Cost in qty [10$ / unit]
-200
-150
-100
-50
0
50
100
9/27/09, 3,
BMS chips
9/27/09, 4,
Cell selection

Small cylindrical

Pouch

Large cylindrical

Prismatic
9/27/09, 5,
Topology selection

Centralized

Modular

Master-slave

Distributed
9/27/09, 6,
Complexity selection

Simple

Sophisticated

analog

digital

go/no go

detailed reports

dumb

smart

2.5~10 $ / cell (20 cells)

10~20 $ / cell (100 cells)
Blade EVs
Genasun
9/27/09, 7,
Complexity selection

Simple

Sophisticated
9/27/09, 8,
Sophisticated BMSs
9/27/09, 9,
AMERICAN EV
Master-slave
"---"
120 cells
9/27/09, 10,
BLACK SHEEP
Master-slave
"Stack V1"
32 cells
9/27/09, 11,
BLACK SHEEP
Master-slave
"Cage V2"
96 cells
9/27/09, 12,
BLACK SHEEP
Master-slave
"Mini V3"
unlimited
9/27/09, 13,
CONVERT THE FUTURE
Centralized
"Flex BMS48"
48 cells
9/27/09, 14,
ELITHION
Distributed
"Lithiumate"
256 cells
9/27/09, 15,
ELITHION
Distributed
"Lithiumate"
256 cells
9/27/09, 16,
ELITHION
Distributed
"Lithiumate"
256 cells
9/27/09, 17,
ELITHION
Distributed
"Lithiumate"
256 cells
9/27/09, 18,
GENASUN
Distributed
"GLD"
24 cells
9/27/09, 19,
LITHIUM BALANCE
Centralized
"C series"
24 cells
9/27/09, 20,
NINGBO YANGMIN
Master-slave
"BMS40"
100 cells
9/27/09, 21,
KJ HALL
Master-slave
"PACKTRAKR"
24 cells
9/27/09, 22,
PETER PERKINS
Distributed
"-"
255 cells
9/27/09, 23,
REAP
Modular
"-"
168 cells
9/27/09, 24,
PRICES
10000
4641.59
Cost [USD]
2154.43
Elithion (1st one)
Ningbo Yangming
Genasun
Black sheep
Reap
Convert the future
American EV
Elithion (100s)
Lithhium balance
KJ Hall
Peter Perkins
1000
464.16
215.44
100
10
21.54
46.42
100
215.44
464.14
Number of cells
9/27/09, 25,
COMPARISON TABLE
9/27/09, 26,
Simple BMSs
9/27/09, 27,
EV Power
Distributed
9/27/09, 28,