EV BMS Project
EV BMS Project
A thesis submitted
In partial fulfilment of the requirements for the award of
The degree of
Bachelor of Technology
In
Electrical Engineering
Submitted by
Date…………....
CANDIDATE’S DECLARATION
We hereby declare that the work presented in the entitled as “Electric Vehicle Battery
Management System with Charge Monitoring and Fire Protection Using Arduino”
in partial fulfilment of the requirement for the award of the degree of “BACHELOR OF
TECHNOLOGY” in Electrical Engineering submitted in the Dept. of Electrical
Engineering of Bineswar Brahma Engineering College, Kokrajhar under Assam Science
and Technology University is a real record of our own work carried out under the
supervisor.
We also declare that the same report has not been submitted anywhere else as a part
of any requirements for any degree/diploma, etc.
Anjelina Dutta
(210910003002)
Kalpita Kalita
(210910003023)
Sahil Akhtar
(210910003043)
Silpisikha Bharadwaz
(210910003045)
DEPARTMENT OF ELECTRICAL ENGINEERING
BINESWAR BRAHMA ENGINEERING COLLEGE
KOKRAJHAR-783370, ASSAM, INDIA
Date…………...
CERTIFICATE OF APPROVAL
This is to certify that the work embodies in project “Electric Vehicle Battery
Management System with Charge Monitoring and Fire Protection Using Arduino”
being submitted by Anjelina Dutta (210910003002), Kalpita Kalita 210910003023),
Nandan Jyoti Ray (210910003031), Sahil Akhtar (210910003043), Silpisikha Bharadwaz
(210910003045) to the department of Electrical Engineering is carried out under my
supervision.
The project work has been prepared as per regulation of Bineswar Brahma Engineering
College, Kokrajhar and I strongly recommended that this project work would be accepted
in partial fulfilment of the requirement for the Degree of Bachelor of Engineering.
We would like to take this opportunity to express our deepest gratitude and special thanks
to the Department of Electrical Engineering and Dr. Dayal Ch. Shill (HOD) of Bineswar
Brahma Engineering College, Kokrajhar, Assam forgiving us the opportunity and guiding
us through the entire project.
We express our deepest thanks to the supervisor who took the initiative and gave us
necessary advice and guidance, and arranged all facilities to make our project easier.
We would also like to express our gratitude towards Dr. Dayal Ch. Shill, Head of the
Dept., Electrical Engineering Dept., Bineswar Brahma Engineering College, Kokrajhar,
Assam for his kind attitude, invaluable guidance, immense help, and encouragement,
which helped in carrying out our project work.
We are extremely thankful to all our department faculty members and our friends who
helped us in successful completion of this project.
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ABSTRACT
The rapid adoption of electric vehicles (EVs) necessitates advanced battery management
systems (BMS) to ensure safety, efficiency, and longevity of the battery packs. This paper
presents an innovative BMS solution integrating charge monitoring and fire protection
functionalities using Arduino. The proposed system continuously monitors the state of
charge (SoC) and state of health (SoH) of the EV battery, employing precise voltage,
current, and temperature sensors. To enhance safety, the system includes a fire protection
mechanism that detects abnormal thermal events and activates appropriate
countermeasures to prevent thermal runaway.
The integration with Arduino provides a cost-effective and flexible platform for real-
time data processing and control. Experimental results demonstrate the effectiveness of the
proposed BMS in maintaining optimal charging conditions and preventing potential fire
hazards, thereby contributing to the overall reliability and safety of electric vehicles.
Additionally, the modular design of the system allows for easy scalability and adaptability
to various EV models, paving the way for broader application in the growing EV market.
This research underscores the importance of robust BMS solutions in fostering a
sustainable and safe electric vehicle ecosystem.
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CONTENTS
CANDIDATE’S DECLARATION
CERTIFICATE OF APPROVAL
ACKNOWLEDGEMENT i
ABSTRACT ii
LIST OF FIGURES iii
LIST OF TABLES iv
ABBREVIATIONS v
CHAPTER 1 INTRODUCTION 1-3
1.1 OVERVIEW 1
1.2 OBJECTIVES 2
1.3 SCOPE 2
CHAPTER 2 METHODOLOGY 4-7
2.1 WORKING PRINCIPLE 4
2.2 BLOCK DIAGRAM 5
2.3 CIRCUIT DIAGRAM 6
2.4 FLOW CHART 7
CHAPTER 3 DESIGN & IMPLIMENTATION 8-9
3.1 SOFTWARE USED FOR SIMULATION 8
3.2 CIRCUIT DESIGN 9
CHAPTER 4 HARDWARE SPECIFICATIONS 10-34
4.1 ARDUINO UNO 10
4.1.1 FEATURES 10
4.1.2 ARDUINO UNO TO ATmega328 PIN 11
MAPPING
4.1.3 COMPASION BETWEEN ATmega48 12
PA, ATmega88PA, ATmega168PA
AND ATmega328P
4.2 REGULATED POWER SUPPLY 13
4.2.1 TRANSFORMER 13
4.2.2 RECTIFICATION 15
4.2.3 DIODE 16
4.2.4 CAPACITOR 17
4.2.5 RESISTOR 17
4.2.6 VOLTAGE REGULATOR 19
4.3 LIGHT EMITTING DIODE (LED) 20
4.4 TEMPERATURE 21
4.4.1 LM35 SENSOR SPECIFICATION 21
4.4.2 LM35 SENSOR PINOUT 22
CONFIGURATION
4.5 VOLTAGE SENSOR 22
4.6 CURRENT SENSOR 23
4.6.1 WORKING PRINCIPLE 24
4.6.2 ACS712 CURRENT SENSOR 24
4.6.3 ACS712 IC PIN CONFIGURATION 25
4.7 BUZZER 25
4.7.1 SPECIFICATIONS 26
4.7.2 TYPES OF BUZZERS 27
4.8 RECHARGEABLE BATTERY (11.2V) 27
4.8.1 FEATURES 28
4.8.2 APPLICATIONS 28
4.8.3 SPECIFICATIONS 28
4.9 LCD UNIT 29
4.9.1 LCD PIN DESCRIPTION 30
4.10 RELAY DRIVER IC 32
4.10.1 ADVANTAGES OF RELAYS 33
4.10.2 DISADVANTAGES OF RELAYS 33
4.10.3 RELAY DRIVER 34
CHAPTER 5 OPERATION OF THE SYSTEM 35-37
5.1 OPERATIONS 35
5.2 FUTURE SCOPE 35
5.3 ADVANTAGES 36
5.4 APPLICATIONS 37
CHAPTER 6 CONCLUSION & FUTURE WORK 38
6.1 CONCLUSION 38
6.2 FUTURE WORK 38
REFERENCES 39
APPENDIX I 40-41
LIST OF FIGURES
FIGURE NO. PAGE NO.
iii
LIST OF TABLES
TABLE NO. PAGE NO.
iv
ABBREVIATIONS
EV Electric Vehicle
BMS Battery Management System
SoC State of Charge
SoH State of Health
SoA Safe Operating Area
PWM Pulse Width modulation
LCD Liquid Crystal Display
MOSFET Metal-Oxide Semiconductor Field Effect
Transistor
PCB Printed Circuit Board
IoT Internet of Things
MCU Microcontroller Unit
IC Integrated Circuit
Li-ion Lithium-Ion
LED Light Emitting Diode
ADC Analog-to-Digital Converter
EEPROM Electrically Erasable Programmable Read-Only
Memory
DMM Digital Multimeter
USB Universal Serial Bus
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CHAPTER 1
INTRODUCTION
1.1 OVERVIEW
Over the past decade, Electric Vehicles (EVs) have become an obvious response to a
topical problem of traditional internal combustion engine vehicles that result in
sustainability and environmental issues. The Battery Management System (BMS) is a key
part of EV technology, designed to maximize the performance, safety and life of the battery
pack. Since batteries are likely to degrade or become dangerous and explode under certain
conditions, charge monitoring is necessary and below we talk about robust BMS with good
battery charge detection and fire protection mechanisms.
The BMS has many important roles to play; some of these include monitoring the
state of charge (SoC), state of health (SoH) and temperature values for the battery.
Important monitoring of these parameters and protecting the battery from causing defects
can prevent safety events. By introducing fire protection measures particularly in the BMS,
means risks like thermal runaway are minimized. Additionally, the charge monitoring
feature of a BMS is essential for keeping track with high accuracy on how much energy
has been stored and discharged to manage power effectively as well as taking measures
into account so that battery life can be extended.
The project exposes how to build an Electric Vehicle Battery Management System
(EV BMS) with Arduino platform. An open-source, versatile and easy-to-use
microcontroller like Arduino would provide an adaptable architecture to develop &
prototype this BMS. We can use Arduino to realize the real-time monitoring of voltage,
current, temperature and fire indication signals associated with EV batteries for further
enhancing their safety. In this report the designed, developed and tested EV BMS is
discussed in relation to charge monitoring and fire safety focusing the attention on
Arduino-based systems as they may cover vital areas of the required functionalities for an
academic but high-tech compliant BMS in modern Electric Vehicles (EV).
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1.2 OBJECTIVES
The main objective of this project is to create a Battery Management System (BMS) for an
Electric Vehicle with charge monitoring and fire protection by using Arduino. Objectively,
the specifics are:
i. Real Time Charge Monitoring: The primary aim of this phase is to develop a
Proteus system that can accurately monitor the state of charge and health of
batteries, timely during operation to ensure safe power levels throughout EV>Error
detection. (Completed in 7th semester)
ii. Simulation in Proteus 8: The purpose of the simulation phase is to test and verify
the design of the electronic circuit in a virtual environment using Proteus software.
Simulation reduces risks by allowing troubleshooting and debugging without the
need for physical components. This helps identify and fix potential issues early,
saving time and resources in the later stages. (Completed in 7th semester)
iii. Hardware Compilation: In this phase, the focus is on translating the simulated
design into actual hardware by assembling the physical components. Hardware
compilation involves gathering the necessary components (like resistors,
capacitors, microcontrollers, etc.), creating PCB (printed circuit board) layouts if
needed, and setting up the circuit according to the specifications verified in Proteus.
(Will be completed in 8th semester)
iv. Hardware Demonstration: The final stage involves demonstrating the fully
assembled hardware to showcase its functionality. This includes showing that the
hardware meets the project requirements, performs as expected, and achieves the
intended goals. It also gives an opportunity to display the project’s usability,
robustness, and readiness for deployment or further development. (Will be
completed in 8th semester)
1.3 SCOPE
2
The scope are as follows:
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CHAPTER 2
METHODOLOGY
There are many BMS design features, with battery pack protection management and
capacity management being two essential features. We’ll discuss how these two features
work here:
1) Battery Monitoring:
• The BMS continuously monitors the voltage, current, and temperature of each
battery cell.
• It calculates the SoC of the battery pack and ensures that the cells are balanced.
• If any cell deviates from the safe operating range, the BMS triggers an alarm and
can take actions like reducing charging current or stopping charging altogether.
2) Motor Control:
• The motor controller receives commands from the BMS and other sensors.
• It regulates the voltage and current supplied to the motor to control its speed and
torque.
• It also monitors the motor's temperature and current to prevent overheating.
3) Charge Monitoring:
• The BMS monitors the charging current and voltage to ensure that they are within
safe limits.
• It also monitors the battery temperature to prevent overheating during charging.
• Once the battery is fully charged, the BMS automatically stops the charging
process.
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4) Fire Protection:
Arduino's Role:
Data Acquisition: The Arduino reads data from various sensors, including voltage,
current and temperature sensors.
Data Processing: It processes the sensor data to determine the state of the battery pack
and the motor.
Decision Making: Based on the processed data, the Arduino makes decisions, such as
controlling the charging process, regulating motor speed, or triggering fire alarms.
Communication: It communicates with other components, such as the BMS and motor
controller, to coordinate their actions.
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2.3 CIRCUIT DIAGRAM
6
2.4 FLOW CHART
7
CHAPTER 3
DESIGN & IMPLEMENTATION
Key Features:
1) Schematic Capture:
• Powerful schematic capture tools for creating complex circuit designs.
• Extensive component libraries, including microcontrollers, digital ICs, analog ICs,
and more.
• Customizable component libraries.
2) PCB Design:
• Advanced PCB layout capabilities for creating professional-quality PCBs.
• Automatic and interactive routing tools.
• Design Rule Check (DRC) to ensure design integrity.
• Gerber file generation for manufacturing.
3) Circuit Simulation:
• Mixed-mode simulation for both analog and digital circuits.
• Real-time simulation with accurate component models.
• Support for a wide range of microcontrollers and peripherals.
• Virtual prototyping to test designs before physical implementation.
4) Virtual System Modelling (VSM):
• Model and simulate complex systems, including hardware and software
components.
• Integrate microcontroller code with circuit simulation.
• Visualize system behaviour and debug issues.
Arduino IDE: The open-source Arduino Software (IDE) makes it easy to write code and
upload it to the board.
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This software can be used with any Arduino board. The Arduino Integrated Development
Environment - or Arduino Software (IDE) contains a text editor for writing code, a
message area, a text console, a toolbar with buttons for common functions and a series of
menus. It connects to the Arduino hardware to upload programs and communicate with
them.
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CHAPTER 4
HARDWARE SPECIFICATIONS
4.1.1 Features
• High Performance, Low Power AVR® 8-Bit Microcontroller.
• Advanced RISC Architecture.
• 131 Powerful Instructions – Most Single Clock Cycle Execution.
• 32 x 8 General Purpose Working Registers.
• Fully Static Operation.
• Up to 20 MIPS Throughput at 20 MHz.
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4.1.2 Arduino Uno to ATmega328 Pin Mapping
When ATmega328 chip is used in place of Arduino Uno, or vice versa, the image below
shows the pin mapping between the two.
The 14 digital input/output pins can be used as input or output pins by using pin
Mode(),digital Read () and digital Write () functions in Arduino programming. Each pin
operates at 5V and can provide or receive a maximum of 40mA current, and has an internal
pull-up resistor of 20-50 K Ohms which are disconnected by default.
Out of these 14 pins, some pins have specific functions as listed below:
• Serial Pins 0 (Rx) and 1 (Tx): Rx and Tx pins are used to receive and transmit
TTL serial data. They are connected with the corresponding ATmega328P USB to
TTL serial chip.
• External Interrupt Pins 2 and 3: These pins can be configured to trigger an
interrupt on a low value, a rising or falling edge, or a change in value.
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• PWM Pins 3, 5, 6, 9, and 11: These pins provide an 8-bit PWM output by using
the analog Write () function.
• SPI Pins 10 (SS), 11 (MOSI), 12 (MISO), and 13 (SCK): These pins are used for
SPI communication.
• In-built LED Pin 13: This pin is connected with a built-in LED. When pin 13 is
HIGH, the LED is on, and when pin 13 is LOW, it is off.
• Analog Pins: There are 6 analog input pins, each providing 10 bits of resolution
i.e., 1024 different values. They measure from 0 to 5 volts but this limit can be
increased by using the AREF pin with the analog Reference () function.
• Analog Pin 4 (SDA) and Pin 5 (SCA): These are used for TWI communication
using the Wire library.
• AREF: Used to provide reference voltage for analog inputs with analog reference
() function.
• Resent Pin: Making this pin LOW, resets the microcontroller.
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instruction can only execute from there. In ATmega48PA, there is no Read-While-Write
support and no separate Boot Loader Section. The SPM instruction can execute from the
entire Flash.
• 230V AC MAINS
• TRANSFORMER
• BRIDGE RECTIFIER (DIODES)
• CAPACITOR
• VOLTAGE REGULATOR (IC 7805)
• RESISTOR
• LED (LIGHT EMITTING DIODE)
The detailed explanation of each and every component mentioned above are as follows:
4.2.1 Transformer
The transformer is essential for converting high AC voltage from the mains (e.g., 120V or
230V) to a lower, more manageable AC voltage. This reduction is crucial for safe operation
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and for providing the right input level to other components in the circuit. Transformers
have two sets of coils: the primary and secondary windings.
The ratio of turns (or coils) between the primary and secondary winding determines
the voltage conversion. By lowering the voltage, the transformer allows the circuit to
handle lower, safer voltages and prevents damage to sensitive components in the power
supply.
If the primary voltage is 240 volts, then the secondary voltage will be x 10 smaller =
24 volts. Assuming a perfect transformer, the power provided by the primary must equal
the power taken by a load on the secondary. If a 24-watt lamp is connected across a 24-
volt secondary, then the primary must supply 24 watts.
Step up transformer:
In case of step-up transformer, primary windings are every less compared to secondary
winding. Because of having more turns secondary winding accepts more energy, and it
releases more voltage at the output side.
In case of step-down transformer, Primary winding induces more flux than the secondary
winding, and secondary winding is having a smaller number of turns because of that it
accepts a smaller number of fluxes, and releases less amount of voltage.
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Some transformers have an electrostatic screen between primary and secondary. This is to
prevent some types of interference being fed from the equipment down into the mains
supply.
4.2.2 Rectification
Rectifiers:
A rectifier is an electrical device that converts alternating current (AC) to direct current
(DC), a process known as rectification. Rectifiers have many uses including as components
of power supplies and as detectors of radio signals. Rectifiers may be made of solid-state
diodes, vacuum tube diodes, mercury arc valves, and other components.
When only one diode is used to rectify AC (by blocking the negative or positive
portion of the waveform), the difference between the term diode and the term rectifier is
merely one of usage, i.e., the term rectifier describes a diode that is being used to convert
AC to DC. Almost all rectifiers comprise a number of diodes in a specific arrangement for
more efficiently converting AC to DC than is possible with only one diode. Before the
development of silicon semiconductor rectifiers, vacuum tube diodes and copper (I) oxide
or selenium rectifier stacks were used.
The Bridge rectifier circuit is shown in figure 4.5, which converts an ac voltage to dc
voltage using both half cycles of the input ac voltage. The Bridge rectifier circuit is shown
in the figure. The circuit has four diodes connected to form a bridge. The ac input voltage
is applied to the diagonally opposite ends of the bridge. The load resistance is connected
between the other two ends of the bridge.
For the positive half cycle of the input ac voltage, diodes D1 and D3 conduct, whereas
diodes D2 and D4 remain in the OFF state. The conducting diodes will be in series with
the load resistance RL and hence the load current flows through RL.
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For the negative half cycle of the input ac voltage, diodes D2 and D4 conduct whereas, D1
and D3 remain OFF. The conducting diodes D2 and D4 will be in series with the load
resistance RL and hence the current flows through RL in the same direction as in the
previous half cycle. Thus, a bi-directional wave is converted into a unidirectional wave.
Input Output
4.2.3 Diode
Diodes in the circuit act as rectifiers, which means they convert the alternating current
(AC) from the transformer to a direct current (DC). DC is essential because most electronic
devices run on DC, not AC. A single diode allows current to pass only in one direction
(forward direction), blocking the other half of the AC cycle.
However, a more efficient design uses four diodes in a bridge rectifier configuration,
which allows the full AC cycle to be used. This results in a pulsating DC output with both
halves of the AC wave converted to positive. This process allows the conversion of AC to
DC, making it usable for DC-powered circuits.
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4.2.4 Capacitor
After rectification, the output is still not a smooth DC but rather a pulsating one. The
capacitor acts as a filter to smooth out these pulses, reducing ripple and creating a more
consistent DC output. The capacitor charges up when the voltage rises and discharges
when the voltage falls, effectively filling in the gaps of the pulsed DC waveform. This
results in a smoother voltage output. By smoothing out fluctuations, the capacitor ensures
that the DC output is closer to a flat, stable voltage, which is more suitable for sensitive
electronic devices.
4.2.5 Resistor
Resistors are sometimes included to limit current, adjust voltage, or help discharge the
capacitor when the power is turned off. They play various roles depending on the specific
design of the power supply. When used as a current limiter, the resistor restricts the amount
of current flowing through certain parts of the circuit. When placed across a capacitor, it
can help safely discharge the stored energy, ensuring there’s no residual charge when the
power supply is switched off. Resistors provide safety and fine-tuning. They prevent
excessive current that could damage components and aid in safely discharging stored
energy.
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Figure 4.8: Resistor
The primary characteristics of a resistor are the resistance, the tolerance, maximum
working voltage and the power rating. Other characteristics include temperature
coefficient, noise, and inductance. Less well-known is critical resistance, the value below
which power dissipation limits the maximum permitted current flow, and above which the
limit is applied voltage. Critical resistance is determined by the design, materials and
dimensions of the resistor.
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4.2.6 Voltage Regulator
A voltage regulator (also called a ‘regulator’) with only three terminals appears to be a
simple device, but it is in fact a very complex integrated circuit. It converts a varying input
voltage into a constant ‘regulated’ output voltage. Voltage Regulators are available in a
variety of outputs like 5V, 6V, 9V, 12V and 15V. The LM78XX series of voltage
regulators are designed for positive input. For applications requiring negative input, the
LM79XX series is used. Using a pair of ‘voltage-divider’ resistors can increase the output
voltage of a regulator circuit.
It is not possible to obtain a voltage lower than the stated rating. We cannot use a 12V
regulator to make a 5V power supply. Voltage regulators are very robust. These can
withstand over-current draw due to short circuits and also over-heating. In both cases, the
regulator will cut off before any damage occurs. The only way to destroy a regulator is to
apply reverse voltage to its input. Reverse polarity destroys the regulator almost instantly.
Use a voltage regulator when the system needs a very precise and stable voltage supply.
The voltage of an unregulated supply will vary depending on a number of factors. If it is
based on house current, then the voltage will vary according to the power company,
equipment, and time of day.
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4.3 LIGHT EMITTING DIODE (LED)
A light-emitting diode (LED) is a semiconductor light source. LEDs are used as indicator
lamps in many devices, and are increasingly used for lighting. Introduced as a practical
electronic component in 1962, early LEDs emitted low-intensity red light, but modern
versions are available across the visible, ultraviolet and infrared wavelengths, with very
high brightness.
The structure of the LED light is completely different than that of the light bulb.
Amazingly, the LED has a simple and strong structure. The light-emitting semiconductor
material is what determines the LED's colour. The LED is based on the semiconductor
diode.
When a diode is forward biased (switched on), electrons are able to recombine with
holes within the device, releasing energy in the form of photons. This effect is called
electroluminescence and the colour of the light (corresponding to the energy of the photon)
is determined by the energy gap of the semiconductor. An LED is usually small in area
(less than 1 mm²), and integrated optical components are used to shape its radiation pattern
and assist in reflection. LED’s present many advantages over incandescent light sources
including lower energy consumption, longer lifetime, improved robustness, smaller size,
faster switching, and greater durability and reliability. However, they are relatively
expensive and require more precise current and heat management than traditional light
sources. Current LED products for general lighting are more expensive to buy than
fluorescent lamp sources of comparable output. They also enjoy use in applications as
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diverse as replacements for traditional light sources in automotive lighting (particularly
indicators) and in traffic signals. The compact size of LED’s has allowed new text and
video displays and sensors to be developed, while their high switching rates are useful in
advanced communications technology.
• Visual signal application where the light goes more or less directly from the LED
to the human eye, to convey a message or meaning.
• Illumination where LED light is reflected from object to give visual response of
these objects.
• Generate light for measuring and interacting with processes that do not involve the
human visual system.
The Temperature Sensor LM35 sensor series are precision integrated-circuit temperature
sensors, whose output voltage is linearly proportional to the Celsius (Centigrade)
temperature.
The LM35 series are precision integrated-circuit LM35 temperature sensors, whose output
voltage is linearly proportional to the Celsius (Centigrade) temperature. The LM35 sensor
thus has an advantage over linear temperature sensors calibrated in ° Kelvin, as the user is
not required to subtract a large constant voltage from its output to obtain convenient
Centigrade scaling. The LM35 sensor does not require any external calibration or trimming
to provide typical accuracies of ±¼°C at room temperature and ±¾°C over a full -55°C to
+150°C temperature range. Low cost is assured by trimming and calibration at the wafer
level. The LM35's low output impedance, linear output, and precise inherent calibration
make interfacing to readout or control circuitry especially easy. It can be used with single
power supplies, or with plus and minus supplies. As it draws only 60 µA from its supply,
it has very low self-heating, less than 0.1°C in still air. The LM35 is rated to operate over
a -55°C to +150°C temperature range, while the LM35C sensor is rated for a -40°C to
+110°C range (-10°C with improved accuracy). The LM35 series is available packaged in
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hermetic TO-46 transistor packages, while the LM35C, LM35CA, and LM35D are also
available in the plastic TO-92 transistor package. The LM35D sensor is also available in
an 8-lead surface mount small outline package and a plastic TO-220 package.
A voltage sensor is an electronic device designed to measure and monitor voltage levels in
a circuit, whether it's DC (Direct Current) or AC (Alternating Current). These sensors work
by detecting the electrical potential difference between two points and converting it into a
form that can be interpreted by control systems, data loggers, or microcontrollers like
Arduino or Raspberry Pi.
Voltage sensors come in various types, but they generally fall into two categories:
resistive dividers and non-contact (or capacitive) types. A resistive divider is a basic type
of voltage sensor that scales down high voltage levels by splitting the voltage
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proportionally across resistors. The lower voltage is then sent to an analog-to-digital
converter (ADC) on a microcontroller, which reads it and calculates the actual voltage
based on the scaling factor. This method is simple but effective for monitoring DC or low-
frequency AC voltages.
On the other hand, non-contact voltage sensors detect voltage without direct contact
with the conductor. These sensors are often used in applications requiring safety, where
direct contact with high voltages would be hazardous. They operate by detecting the
electric field generated by AC voltage and use this field to infer the voltage level.
For more complex applications, voltage sensors may also include additional circuitry
for signal conditioning, noise reduction, or isolation. Isolation, especially in high-voltage
environments, is essential to protect sensitive electronics from potential surges or spikes.
This way, voltage sensors play a crucial role in power systems, automation, and safety
applications, allowing for precise monitoring and control over voltage levels.
A device that is used to detect & also change current to assessable output voltage is known
as a current sensor. This output voltage is simply proportional to the current flow
throughout the measured path. After that, this output voltage signal is used to display the
current measured within an ammeter, for controlling purposes or simply stored for more
analysis within a data acquisition system. So, this is the function of a current sensor.
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Figure 4.15: Current sensor
The working principle of the current sensor is; once current is supplied throughout a circuit
or a wire then a voltage drop takes place and also magnetic field will be generated nearby
the current-carrying conductor. So, there are two kinds of current sensing direct current
sensing & indirect current sensing. Direct sensing mainly depends on Ohm’s law whereas
indirect sensing depends on Ampere’s & Faraday’s law. Direct Sensing is used to measure
the voltage drop associated with the flow of current throughout passive electrical
components. Similarly, indirect sensing is used to measure the magnetic field nearby a
current-carrying conductor. After that, the magnetic field which is produced is used for
inducing proportional current o voltage which is afterward changed to use measurement or
control purposes.
Current sensors are designed in different types like wireless, analog, and digital. These
are used as sensing devices based on the type of benefit. These sensors will monitor the
current values continuously in the appliances or machines within various applications.
The ACS712 Current Sensor is used to measure both AC & DC currents precisely. So, this
current sensor is based on Hall Effect & this IC includes an inbuilt Hall Effect device. The
output of this sensor is an analog voltage that is proportional to AC/DC currents. The
working of this current sensor circuit is quite simple. Once current is supplied from Pins
1,2 and 3,4 throughout the conduction lane, then it produces a magnetic field which is
detected by the hall effect sensor. After that, it is changed into proportional o/p voltage.
So, this equivalent o/p voltage will be attained from the pin-1 of the ACS712 IC.
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4.6.3 ACS712 IC Pin Configuration
The ACS712 IC includes 8-pins where each pin and its function are discussed below:
• Pins 1 & 2 (IP+): These are positive terminals that are used for sensing current.
• Pins 3 & 4 (IP-): These are negative terminals that are used for sensing current.
• Pin5 (GND): This is a Ground pin.
• Pin6 (FILTER): This pin is used for the external capacitor that sets the bandwidth.
• Pin7 (VIOUT): This is an analog output signal pin.
• Pin8 (VCC): This is a power supply pin.
The IC ACS712 is a low-cost Hall Effect current sensor used to measure up to 20A
current. This IC includes a copper conduction lane through which the flow of current is
measured. The o/p voltage of this is proportional to the input flow of the current.
4.7 BUZZER
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the direction Thus, when AC voltage is applied across electrodes, the bending is repeated,
producing sound waves in the air.
The pin configuration of the buzzer is shown above. It includes two pins namely
positive and negative. The positive terminal of this is represented with the ‘+’ symbol or a
longer terminal. This terminal is powered through 6Volts whereas the negative terminal is
represented with the ‘-’ symbol or short terminal and it is connected to the GND terminal.
4.7.1 Specifications
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4.7.2 Types of Buzzers
• Piezoelectric
• Electromagnetic
• Mechanical
• Electromechanical
• Magnetic
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4.8.1 Features
4.8.2 Applications
• Electric Scooter
• Electric Bicycle
• E-Skate Board
• Electric Motorcycle
• E-Wheel Chair
• Electric Tool
• Drone
• Power Bank
4.8.3 Specifications
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• Capacity: 1200mAh
• Weight: 35gm
• Height: 65mm
• Diameter: 18mm
In this project, a three battery pack is used which consist of 11.2 volts.
LCD screens are available in a wider range of screen sizes than CRT and plasma
displays, with LCD screens available in sizes ranging from tiny digital watches to very
large television receivers. Since LCD screens do not use phosphors, they rarely suffer
image burn-in when a static image is displayed on a screen for a long time, e.g., the table
frame for an airline flight schedule on an indoor sign. LCDs are, however, susceptible to
image persistence. The LCD screen is more energy-efficient and can be disposed of more
safely than a CRT can. Its low electrical power consumption enables it to be used in
battery-powered electronic equipment more efficiently than CRTs can be. By 2008, annual
sales of televisions with LCD screens exceeded sales of CRT units worldwide, and the
CRT became obsolete for most purposes. One of the most common devices attached to a
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micro controller is an LCD display. Some of the most common LCD connected to the
many microcontrollers are 16x2 and 20x2 displays. This means 16 characters per line by
2 lines and 20 characters per line by 2 lines, respectively.
LCD (Liquid Crystal Display) screen is an electronic display module and find a wide range
of applications. A 16x2 LCD display is very basic module and is very commonly used in
various devices and circuits. These modules are preferred over seven segments and other
multi segment LEDs. The reasons being: LCDs are economical, easily programmable,
have no limitation of displaying special & even custom characters (unlike in seven
segments), animations and so on.
A 16x2 LCD means it can display 16 characters per line and there are 2 such lines. In
this LCD each character is displayed in 5x7 pixel matrix. This LCD has two registers,
namely, Command and Data. The command register stores the command instructions
given to the LCD. A command is an instruction given to LCD to do a predefined task like
initializing it, clearing its screen, setting the cursor position, controlling display etc. The
data register stores the data to be displayed on the LCD. The data is the ASCII value of the
character to be displayed on the LCD.
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RS: RS is the register select pin. We need to set it to 1, if we are sending some data to be
displayed on LCD. And we will set it to O if we are sending some command instruction
like clear the screen (hex code 01).
RW: This is Read/write pin, we will set it to 0, if we are going to write some data on LCD.
And set it to 1, if we are reading from LCD module. Generally, this is set to 0, because we
do not have need to read data from LCD. Only one instruction "Get LCD status", need to
be read sometimes.
EN: This pin is used to enable the module when a high to low pulse is given to it. A pulse
of 450 ns should be given. That transition from HIGH to LOW makes the module
ENABLE.
VSS: This refers to the ground pin (0V reference) in a circuit and would be the most
negative part of the power supply, serving as the return path for the current to the power
supply.
Finally, the data bus consists of 4 or 8 lines (depending on the mode of operation
selected by the user). In the case of an 8-bit data bus, the lines are referred to as DB0, DB1,
DB2, DB3, DB4, DB5, DB6, and DB7.
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4.10 RELAY DRIVER IC
Here are some common features and characteristics of relay driver ICs:
1. Current Amplification: Relay coils typically require more current than what a
standard digital output pin from a microcontroller can provide. Relay driver ICs
amplify the current to meet the requirements of the relay coil.
2. Voltage Regulation: They may include voltage regulation circuitry to ensure that
the relay coil receives a stable and appropriate voltage.
3. Protection Features: Relay driver ICs often include protective features such as
flyback diodes to suppress voltage spikes that occur when the relay coil is de-
energized.
4. Input Compatibility: They are designed to be easily controlled by digital signals
from
microcontrollers, microprocessors, or other digital control circuits.
5. Isolation: Some relay driver ICs provide electrical isolation between the control
circuit and the relay coil. This is important for safety and to prevent interference
between circuits.
6. Multiple Channels: Many relay driver ICs come with multiple channels, allowing
them to control multiple relays independently.
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Popular relay driver ICs include the ULN2003, ULN2803, and MCP23017. When
selecting a relay driver IC, it's essential to consider the specific requirements of your
application, including the voltage and current ratings of the relay, the number of channels
needed, and any additional features required for your circuit. Always refer to the datasheet
of the specific IC you are using for detailed information on its specifications and usage
guidelines.
• Relays can switch AC and DC; transistors can only switch DC.
• Transistors cannot, relays can switch high voltages.
• Relays are a better choice for switching large currents (> 5A).
• Many contacts can switch at once with relays.
• Relay can control high-power circuits with low-power signals.
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4.10.3 Relay Driver
The current needed to operate the relay coil is more than can be supplied by most chips
(op. amps etc), as shown in the diagram below, so a transistor is usually needed.
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CHAPTER 5
OPERATION OF THE SYSTEM
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II. Advanced Battery Technologies: Innovations in battery chemistry, such as solid-
state batteries and lithium-sulphur batteries, will require more sophisticated BMS
to monitor and optimize performance.
III. Enhanced Safety: As battery packs become larger and more powerful, BMS will
need to incorporate advanced safety protocols to prevent overcharging,
overheating, and other risks.
IV. Integration with Smart Technologies: The integration of BMS with IoT and AI
can enhance real-time monitoring, predictive maintenance, and energy
management, improving overall vehicle efficiency.
V. Cost Reduction: As hybrid vehicles become more mainstream, cost-effective
BMS solutions will be crucial for manufactures to remain competitive.
VI. Vehicle-to-Grid (V2G) Systems: The growing interest in V2G technology will
necessitate BMS capable of facilitating bi-directional energy flow between the
vehicle and the grid.
5.3 ADVANTAGES
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VIII. User Interface: It provides real-time data and diagnostics to the driver, enhancing
user awareness and control over the vehicle’s energy usage.
IX. Better Thermal Management: Fire protection systems often include thermal
management features, ensuring the battery operates at optimal temperatures and
preventing overheating.
5.4 APPLICATIONS
I. Battery Monitoring: BMS continuously monitors the state of charge (SoC), state
of health (SoH), and temperature of each battery cell, ensuring optimal
performance and longevity.
II. Cell Balancing: It manages the charging and discharging of individual cells to
maintain balance, preventing overcharging or deep discharging, which can damage
the cells.
III. Thermal Management: BMS regulates the temperature of the battery pack,
activating cooling or heating systems as necessary to maintain optimal operating
conditions.
IV. Safety Management: It provides protection against over-voltage, over-current,
and short circuits, ensuring safe operation of the battery system.
V. Energy Management: BMS optimizes the energy flow between the internal
combustion engine, electric motor, and battery, enhancing overall vehicle
efficiency and performance.
VI. Lifecycle Management: It tracks battery usage and performance over time,
helping to predict when maintenance or replacement is needed, thus, maximizing
the vehicle’s operational lifespan.
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CHAPTER 6
CONCLUSION & FUTURE WORK
6.1 CONCLUSION
The development of an Arduino-based BMS for EVs with integrated charge monitoring
and fire protection offers a low cost, scalable solution for enhancing safety and efficiency
in EVs. By continuously monitoring battery parameters, such as voltage, current, and
temperature, this BMS can maintain optimal charge levels and ensure safe battery
operations, reducing risks associated with overcharging and overheating. The inclusion of
fire protection measures, such as temperature-triggered alerts and automatic disconnect
systems, adds a critical layer of safety. This project demonstrates the feasibility and
effectiveness of using Arduino for real-time battery management, paving the way for more
accessible EV technology in both commercial and personal applications. Future
improvements may include enhanced data analytics and integration with IoT for remote
monitoring. The Arduino-based BMS is effective in reducing emissions, enhancing battery
life, and ensuring cell management.
I. Designing and integrating the hardware for voltage and current measurement. This
allows the real time monitoring of battery charge.
II. This circuit handles both the charging and discharging cycles with adequate safety
features.
III. Designing of fire prevention mechanism like Halon system.
IV. Thermal management system can be introduced such as heat sinks, cooling fans,
etc.
V. There is use of thermal sensors like thermistor or thermocouple to detect excessive
heat in battery pack.
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REFERENCES
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APPENDIX I
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Snapshot 3: Simulation shows temperature sensor and current sensor
Snapshot 4: Simulation shows voltage sensor and the result is system is working ok
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