The Ultimate Guide to Become a Skilled Battery Management Systems Engineer

Do you know that the device you are reading this article on, deploys a rechargeable battery? Batteries power all the portable electronic devices available in the market. The capacity may vary from a few watt hours (Wh) to a few Kilowatt-hours (kWh) based on the power requirements. For example, the power of the battery used in your mobile phone will be around 4.4 V, whereas, in an electric vehicle, it can be up to 100 kWh.

When a Lithium-ion battery is used for high-power requirements, an efficient Battery Management System (BMS) is essential. The primary function of a BMS is to protect the cells from thermal runaway and maintain SOC (State of Charge) and SOH (State of Health). Let us discuss in detail the need for Battery Management Systems and the skills needed to build a career in battery technology.

Why is a BMS System Needed?

• In an electric vehicle, thousand of cells are connected in series and parallel to cater for the power requirements. Each cell, while charging and discharging, produces some amount of heat. But the cumulative effect of the generated heat is undesirable and can sometimes lead to an explosion. A BMS system constantly monitors the temperature inside the battery pack using thermal sensors and regulates it.
• Since many cells inside the battery pack are connected in parallel and series, the charge flows in and out will be unequal. It may lead to overcharging cells and a reduced life cycle, if not addressed. To avoid this, the BMS system checks each cell's charge level and balances it.

Construction of a Battery Management System

A BMS system is a complex model of hardware and software systems. 

- The Hardware part includes cells, cell holders, nickel strips, PCB, PVC heat sink film, sensors and many other components. It is essential for providing support and sealing different components. Improper sealing can lead to disastrous situations like leaking and short-circuiting.

- Embedded Software makes the BMS systems actively communicate within the battery pack in sending signals. The core intelligence system monitors various parameters to maintain the SOC and SOH of the battery.

Software Tools Needed for Designing BMS

MATLAB Simulink

Simulink is a tool used for model-based development that is integrated into MATLAB. Using it, you can develop and test models for power electronic applications. On this platform,

• You can develop closed-loop algorithms for fault detection.
• Test and validate the functionality of the circuit.
• Estimation of SOC and SOH.
• Generation of C codes.
• Developing prototypes using microcontrollers.

OpenFOAM

It is an open-source tool used for developing customised solvers for CFD simulations. Using OpenFOAM, you can

• Determine the maximum threshold temperature of the battery pack
• Efficiently manage the temperate inside the battery pack and individual cells.
• Perform thermal modelling simulation of a BMS.

ANSYS Fluent

It is a popular CFD (Computational Fluid Dynamics) tool for solving fluid dynamics problems. It provides a solution for BMS development and helps engineers in

• Ensuring the functional safety of BMS.
• Test embedded software and validate the same.
• Design and validation of Battery Management System.

GT-SUITE

Developed by Gamma Technologies, it provides many system-level simulation solutions for engineering across different domains, including battery technology. It helps in

• Electrochemical process modelling of Lithium-ion cells.
• Determine the temperature distribution of an electrical-equivalent battery model.
• Verification of thermal management techniques.

Who is BMS Design Engineer?

A BMS engineer's roles and responsibilities include

• Integrating software to BMS hardware system.
• Designing, developing and simulating thermal components: Heat exchanger, battery modules, cooling plates and venting systems.
• Preparing technical documentation based on a detailed analysis of the battery pack.
• Developing the power train module.
• Ensuring that the design meets the safety requirements and industry standards.
• Negotiating with vendors for procurement activities.
• Assisting in the mass production process.
• Analysing the vehicle environment and understanding the requirements of the battery pack.
• Performing various simulations to test and validate the functions of BMS.
• Communicate across different departments to understand the full scope of designing BMS.

Essential Skills for a Battery Design Engineer

To design an efficient Battery Management System, you must possess a basic knowledge of the different domains. Here is a list of skills that are in demand.

• A basic knowledge of EV technologies.
• A good grasp of circuit modelling and simulation.
• Hands-on experience in working with design and simulation tools(You can easily acquire this by working on projects or doing an internship).
• In-depth knowledge of fluid flows and thermal management systems.
• Know-how in testing and validating the functionality of BMS.
• Programming skills in developing C codes.
• Proficiency in using different software tools needed for designing BMS.
• Understanding the needs and functionalities of different sensors.
• Ability to interpret the data and analyse the causes of failure.
• Good analytical and communication skills. 

The Future Scope of BMS Engineers

Today the number of electric vehicles on the road is less than 1%, but in the next decade, it is expected to increase up to 13%. As batteries are the heart of EVs and BMS is the brain, the demand for this position will continue to increase. 

The average salary of a battery design engineer in India is around 6.5 Lakhs; in the US, it is around $88,400 yearly. Many top OEMs, including OLA Electric, Tesla, Mercedes Benz, Tata, Bosch and Mahindra, are hiring BMS engineers. It is the right time for you to kick-start your career as a battery design engineer.

How To Become a Skilled BMS Engineer?

We have discussed the software tools and skills needed for a BMS engineer. You must start gaining proficiency in those aforementioned tools and widen your knowledge base. You can choose an online course or use free study materials, but it is a long process. Also, prepare for an interview as it is the gateway to a lucrative career. You can learn some frequently asked BMS interview questions to speed up your preparation.

On this line, Skill-Lync can help you to efficiently use your time in upskilling. We offer a BMS Engineer course which will take you through the technical aspects of a battery. Also, we provide placement training with mock interviews and resume-building sessions. 

It will help you to begin your career as a BMS engineer. For more guidance, feel free to talk to our experts.<link>