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LEDs
Analog Front End
BQ76930
SVS
TPS3839
Battery Management
Controller
MSP430
System +
System -
I
2
C
3.3 V
UART
SBW
Cell Balancing
10X CSD13381F4
Protection FETs
2X2 CSD19536KTT
TEMP
LMT01
1
TIDUAR8B–September 2015–Revised May 2016
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Copyright © 2015–2016, Texas Instruments Incorporated
10s Battery Pack Monitoring, Balancing, and Comprehensive Protection, 50-
A Discharge Reference Design
TI Designs
10s Battery Pack Monitoring, Balancing, and
Comprehensive Protection, 50-A Discharge Reference
Design
TI Designs
The TI Design TIDA-00449 is a ready, tested hardware
platform for 10 cells in series battery pack monitoring,
balancing, and protecting for power tools. Power tools
increasingly use highly power dense Li-ion or Li-iron
phosphate cell-based battery packs that need to be
protected from explosion due to incorrect charging or
discharging. The TIDA-00449 also achieves thermal
requirements for power tool battery packs when
discharging at high continuous current.
Design Resources
TIDA-00449
Design Folder
BQ7693003DBT Product Folder
CSD19536KTT Product Folder
CSD23381F4 Product Folder
CSD13381F4 Product Folder
LMT01LPG Product Folder
MSP430G2553IPW20 Product Folder
TPS3839G33 Product Folder
ASK Our E2E Experts
WEBENCH® Calculator Tools
Design Features
• Battery Pack Designed for 36-V (10-Cell Li-Ion or
Li-Iron Phosphate Based), 50-A Max Continuous
Discharge Current
• Monitors Cell Voltages, Pack Current, Pack
Temperatures, Balances Cells, and Protects by
Controlling Charge or Discharge FETs
• Hardware Protection For Overcurrent in Discharge,
Short Circuit in Discharge, Overvoltage, and
Undervoltage
• Ultra-Small Footprint, Low On-Resistance, Low Q
g
and Q
gd
FemtoFET™ MOSFETs on Board for
Passive Balancing Current up to 150 mA per Cell
• Low Quiescence Current, Ultra-Low Power State
for Shipment
• Onboard Host Microcontroller to Enable
Implementation of Battery Fuel Gauging
Featured Applications
• Battery-Powered Power Tools
• Battery-Powered Garden Tools
• Vacuum and Garden Robots
An IMPORTANT NOTICE at the end of this TI reference design addresses authorized use, intellectual property matters and other
important disclaimers and information.
System Description
www.ti.com
2
TIDUAR8B–September 2015–Revised May 2016
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Copyright © 2015–2016, Texas Instruments Incorporated
10s Battery Pack Monitoring, Balancing, and Comprehensive Protection, 50-
A Discharge Reference Design
1 System Description
The battery packs of power and garden tools are more often using Li-ion, Li-polymer, or Li-iron phosphate
cell types. These chemistries are good in both volumetric and gravimetric energy density. While these
chemistries provide high energy density and thereby lower volume and weight as an advantage, they are
associated with safety concerns. Those concerns are undervoltage (UV) and overvoltage (OV), over
temperature (OT), and overcurrent (OC), all which contribute to the accelerating cell degradation and may
lead to thermal runaway and explosion.
Combined with the increase in number and size of the battery packs, those safety concerns lead to an
increase need of protection, monitoring and balancing. Furthermore space and thermal considerations are
also important in battery pack designs.
The TI Design TIDA-00449 provides a tested hardware platform for the cell monitoring, balancing,
protecting, and gauging of the battery pack, which uses 10 cells of Li-ion or Li-iron phosphate in series.
This design consists of:
• An analog front end (AFE) that monitors the voltage of cells and the battery pack as well as the current
and temperature of the pack. The AFE also includes comprehensive protection, including UV and OV,
short circuit, and OC protection. It also drives the cell balancing circuit.
• A microcontroller (MCU) used as a battery management controller enables configuring of the AFE’s
parameters, doing the gas gauging algorithm, doing the cell balancing scheme, handling the fault, and
communicating with the system outside the battery pack.
• Protection FETs controlled by the AFE that open the circuit when a fault occurs during charge or
discharge.
LEDs
Analog Front End
BQ76930
SVS
TPS3839
Battery Management
Controller
MSP430
System +
System -
I
2
C
3.3 V
UART
SBW
Cell Balancing
10X CSD13381F4
Protection FETs
2X2 CSD19536KTT
TEMP
LMT01
www.ti.com
Design Features
3
TIDUAR8B–September 2015–Revised May 2016
Submit Documentation Feedback
Copyright © 2015–2016, Texas Instruments Incorporated
10s Battery Pack Monitoring, Balancing, and Comprehensive Protection, 50-
A Discharge Reference Design
2 Design Features
The TIDA-00449 uses a 10S3P battery pack (30 to 42 V, 12.6 Ah).
The design must be capable of delivering a continuous discharge current of 50 A and a maximum charge
current of 9 A.
The TIDA-00449 must include a comprehensive protection including:
• UV protection at 2.75 V
• OV protection at 4.3 V
• OC protection at 200 A for 40 ms
• Short circuit protection at 300 A for 200 µs
As this battery pack consist of 10 cells in series, cell balancing is also critical. The targeted balancing
current is 150 mA at 4.2 V.
3 Block Diagram
Figure 1 shows the system block diagram.
Figure 1. TIDA-00449 System Block Diagram
SENSE _ OCD _ MAX
100 mV
R 0.5 m
200 A
= = W
SENSE _ SCD _MAX
200 mV
R 0.667 m
300 A
= = W
THRESHOLD
SENSE
LIM
V
R
I
=
Circuit Design and Component Selection
www.ti.com
4
TIDUAR8B–September 2015–Revised May 2016
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Copyright © 2015–2016, Texas Instruments Incorporated
10s Battery Pack Monitoring, Balancing, and Comprehensive Protection, 50-
A Discharge Reference Design
4 Circuit Design and Component Selection
4.1 AFE
4.1.1 Part Selection
The bq769x0 family of robust AFE devices serves as part of a complete pack monitoring and protection
solution for next-generation high-power systems such as power tools. The bq769x0 is designed with low
power in mind: Sub-blocks within the IC may be enabled or disabled to control the overall chip current
consumption, and a SHIP mode provides a simple way to put the pack into an ultra-low power state.
The bq76930 supports up to 10-cell series or typical 36-V packs. This AFE can measure a variety of
battery chemistries, including Li-ion, Li-iron phosphate, and more. Through I
2
C, a host controller can use
the bq76930 to implement many battery pack management functions such as monitoring (cell voltages,
pack current, pack temperatures), protection (controlling charge or discharge FETs), and balancing.
Integrated ADCs enable a purely digital readout of critical system parameters with calibration handled in
TI’s manufacturing process.
4.1.2 Current Sensing
One of the first steps when designing a battery pack monitoring, balancing, and protection circuit is to
choose the sense resistor. To do this, consider what are the short circuit current limit (SCD) and the
overcurrent limit (OCD) as well as the voltage threshold setting used by the AFE. Please note that further
current limit thresholds could be implemented in the battery management controller for a more elaborate
protection scheme (see Section 4.2.3.1).
This design aims at ~300 A for 200 μs for SCD and ~200 A for 40 ms for OCD. The voltage threshold
settings are available on page 36 and 37 of the bq76930 datasheet (SLUSBK2). The maximum values for
the voltage thresholds are 200 mV for SCD and 100 mV for OCD. The Ohm’s law gives a 0.67-mΩ
maximum sense resistor value for SCD and 0.5-mΩ maximum sense resistor value for OCD as shown in
Equation 2 and Equation 3.
(1)
So,
(2)
(3)
Therefore, R
SENSE
was chosen equal at 0.5 mΩ.
The voltage threshold is now recalculated to have 300 A with a 0.5-mΩ sense resistor. Reusing
Equation 2 gives a 150-mV voltage threshold for SCD. 150 mV is not in the table on page 36 of the
bq76930 datasheet (SLUSBK2), but 155 mV is; therefore, 155 mV is used to give 310 A for SCD.
The maximum continuous current of this application is 50 A, which means that with a sense resistor with
0.5-mΩ, 1.25-W power is being dissipated.
With all this taken into account, including some margin on the power dissipation, three units of 1.5 mΩ,
2512 1% 2-W resistors are used in parallel. The voltage across the sense resistor is continuously
monitored using SCD and OCD comparators for the protection. This voltage is also fed to a 16-bit
integrated ADC, commonly referred to as the coulomb counter (CC), which measures the accumulated
charge across the current sense resistor.
www.ti.com
Circuit Design and Component Selection
5
TIDUAR8B–September 2015–Revised May 2016
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Copyright © 2015–2016, Texas Instruments Incorporated
10s Battery Pack Monitoring, Balancing, and Comprehensive Protection, 50-
A Discharge Reference Design
4.1.3 Protection FETs
Now that the sense resistor is selected, the next step is to design the protection FETs.
The purpose of these FETs is to open the circuit in case of a fault. Table 1 shows when the discharge
FET (DSG) and the charge FET (CHG) are set to open.
Those two FETs are controlled separately to use the battery pack in a safe condition even if some fault
occurs. For example, if the battery pack is fully discharged, the UV fault will be triggered, which opens the
DSG FET, preventing further discharge current to flow. Meanwhile, the CHG FET stays closed, allowing a
charging current to flow once applied.
Table 1. CHG and DSG Response to Different Events
EVENT CHG FET OPEN DSG FET OPEN
OV fault Yes —
UV fault — Yes
OCD fault — Yes
SCD fault — Yes
ALERT override Yes Yes
DEVICE_XREADY is set Yes Yes
Enter SHIP mode from NORMAL Yes Yes
In cases where protection FETs are not required, the TIDA-00449 provides two pads for the user to
bypass the protection FETs. More details are provided in Section 7.4.
4.1.3.1 FET Selection
To select a FET, take four main parameters into account: the voltage, current, thermal performance, and
the switching time of the FET.
The voltage rating of the FET must be higher than approximately 5-V DC per cell in series and 10-V
transient per cell in series. In this design, 10 cells are used in series, which means that the FETs (Q13,
Q14, Q15, and Q16) should be rated higher than 50-V DC and 100-V transient.
The current requirements of the TIDA-00449 are 75-A continuous, 300 A for 400-μs, and 200 A for 40-ms
transient.
Concerning the thermal performance, an R
DSON
value as low as possible is preferred to minimize the
power losses across those FETs. The package is also a key element, as it should be capable to withstand
the thermal losses and to dissipate effectively the thermal losses to the PCB or heat sink.
Finally, the time required to turn on and off the FET is critical. It is mainly impacted by the strength of the
gate driver in the BQ76930 AFE and on the gate charge of the FET (more details in Section 4.1.3.2).
With all these parameters in mind, this design uses two CSD19536KTT in parallel. The CSD19536KTT is
a 100-V, 2-mΩ, ultra-low Q
g
and Q
gd
D
2
PAK (TO-263) NexFET™ power MOSFET.
剩余35页未读,继续阅读
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