CAUTION - WARNING

Lithium and other batteries are dangerous and must be treated with care.

NXP has battery emulators that may be used during testing: https://www.nxp.com/design/development-boards/analog-toolbox/6-cell-battery-pack-to-supply-mc33772-evbs:BATT-6EMULATOR

Important Notice

NXP provides the enclosed product(s) under the following conditions:

This reference design is intended for use of ENGINEERING DEVELOPMENT OR EVALUATION PURPOSES ONLY. It is provided as a sample IC pre-soldered to a printed circuit board to make it easier to access inputs, outputs, and supply terminals. This reference design may be used with any development system or other source of I/O signals by simply connecting it to the host MCU or computer board via off-the-shelf cables. Final device in an application will be heavily dependent on proper printed circuit board layout and heat sinking design as well as attention to supply filtering, transient suppression, and I/O signal quality.

The goods provided may not be complete in terms of required design, marketing, and or manufacturing related protective considerations, including product safety measures typically found in the end product incorporating the goods.

Due to the open construction of the product, it is the user's responsibility to take any and all appropriate precautions with regard to electrostatic discharge. In order to minimize risks associated with the customers applications, adequate design and operating safeguards must be provided by the customer to minimize inherent or procedural hazards. For any safety concerns, contact NXP sales and technical support services. Should this reference design not meet the specifications indicated in the kit, it may be returned within 30 days from the date of delivery and will be replaced by a new kit.

NXP reserves the right to make changes without further notice to any products herein. NXP makes no warranty, representation or guarantee regarding the suitability of its products for any particular purpose, nor does NXP assume any liability arising out of the application or use of any product or circuit, and specifically disclaims any and all liability, including without limitation consequential or incidental damages.

Typical parameters can and do vary in different applications and actual performance may vary over time. All operating parameters, including Typical, must be validated for each customer application by customer’s technical experts.

NXP does not convey any license under its patent rights nor the rights of others. NXP products are not designed, intended, or authorized for use as components in systems intended for surgical implant into the body, or other applications intended to support or sustain life, or for any other application in which the failure of the NXP product could create a situation where personal injury or death may occur. Should the Buyer purchase or use NXP products for any such unintended or unauthorized application, the Buyer shall indemnify and hold NXP and its officers, employees, subsidiaries, affiliates, and distributors harmless against all claims, costs, damages, and expenses, and reasonable attorney fees arising out of, directly or indirectly, any claim of personal injury or death associated with such unintended or unauthorized use, even if such claim alleges NXP was negligent regarding the design or manufacture of the part.

The RDDRONE-BMS772 integrates the following functions and features:

• LiPo Battery from 3s to 6s, with stack voltage ranging from 6V to 26V

• ambient temperature range from -20°C to 60°C

• measures battery stack and cell voltages with an accuracy of +/-5mV, battery charge or discharge current up to 200A peak and 90A* DC with an accuracy of 1% for the complete chain and cell temperature with an accuracy of +/- 2°C (including AFE, PCB and NTC inaccuracies)

• active cell balancing during charging

• offers a deep sleep mode (for transportation and storage) with <80μA leakage current, as well as an automatic sleep mode with <200μA current consumption on the battery.

• allows authentication of the battery

• allows diagnostics to verify the safe operation of the battery

• allows CAN, I²C and NFC communication

• implements SWD and JTAG debugging interfaces, works with standard Segger J-Link and other debuggers

• implements DCD-LZ combined debug and uart console interface for use with PX4 DroneCode and HoverGames platforms

Note: The 90A DC maximum current is obtained only when all MOSFETs and heatsinks are mounted. See Power MOSFETs and heatsinks.

The RDDRONE-BMS772 is a standalone BMS Reference Design suitable for mobile robotics such as drones and rovers, supporting 3-6 cell batteries.

The RDDRONE-BMS772 is a standalone BMS Reference Design suitable for mobile robotics such as drones and rovers, supporting 3-6 cell batteries.

Other uses include portable electronics and equipment needing better battery management

• eScooters, ebikes

• high end power tools

• portable medical devices (Pulse oximeter, portable pumps, electric portable refrigerator)

• backup battery system

• outdoor monitoring/measuring equipment

It is an open hardware and software design and useful leverages components used in general purpose automotive and high-reliability industrial applications. The BCC device performs ADC conversion on the differential cell voltages and currents. It is capable of very accurate battery charge coulomb counting and battery temperature measurements.

The NXP MC33772 is a 6 cell BCC. If higher cell counts are required this could be redesigned to daisy chain multiple BCC chips or switch to a larger cell count BCC such as the MC33771. These parts are all automotive grade Li-Ion battery cell controller IC designed for automotive and industrial applications such as HEV, EV, ESS, UPS systems

The BMS772 also features an S32K146/144 automotive grade S32K Microcontroller. These are rugged M4 core processors part of a scalable family of AEC-Q100 qualified 32-bit Arm® Cortex®-M4F and Cortex-M0+ based MCUs

An NTAG5 Boost NFC NFC Forum-compliant I2C bridge is also onboard and appears as an NFC contactless tag to the external world, and interfaces internally in a simple manner similar to an EEPROM for easy secure query of status or setting of parameters using an external NFC device such as a cell phone. In a practical sense this allows an end user to check multitudes of batteries that may be in storage just by hovering their cell phone over them.

An A1007 is an enhanced version of A1006 secure authenticator IC which includes monotonic counters and secure flags. These can be used to prove the battery pack is genuine and has not been tampered with as well as securely count charge cycles, and permanently flag negative events such as over discharge. The Secure Authenticator IC is a secure tamper-resistant authentication IC, which offers a strong cryptographic solution intended to be used by device manufacturers to prove the authenticity of their genuine products

Finally, the BMS communicates with a host such as a Drone Flight Management Unit (FMU) through UAVCAN or I2C/SMBus.

As we learn of specific needs for specific use cases they will be noted here:

• PX4 BMS specification and working group discusses the need to provide 5V power to a drone before activating the actual battery power supply. The intent is to allow the host to identify the battery characteristics to avoid a catastrophic mismatch. Conceptually there is a need to supply 5V through the CAN /SBUS connectors to allow a host-side processor to power up and query the battery for compatibility with the drone. i.e. do not power up a 12S battery on a drone that only is designed for 3S or 4S

  • This functionality can be tested with the current revision of the board given a few jumper wires to the CAN/SBUS connectors. As built the +5V power is NC

  • Not clear if the battery can be asleep then woken up with a button press to supply power.

  • The 5V supply MAY only need to power a small MCU on the host side and not the complete host-side FMU. The small MCU could do the BMS query and then choose to power up the battery if in compliance.

• May be a trend toward 4 LEDS to show battery gauge status visually. We have one RGB led which we intend to flash a sequence and color to show battery status

  • Extra LEDs could be added on the expansion header

• The BMS itself doesn't regulate charging current or voltage, and needs a simple CC/CV charger. It can however balance it's own cells and disconnect the load. This situation could be improved by making a charger that talks with the battery over CAN and helps properly manage current and voltage, or even additional circuitry on board to manage this.

The RDDRONE-BMS772 is a standalone BMS Reference Design suitable for mobile robotics such as drones and rovers, supporting 3-6 cell batteries. Other portable electronics and equipment, such as scooters, power tools, portable medical devices could also benefit from referencing this design. If higher cell counts are required this could be redesigned to daisy chain multiple BCC chips or switch to a larger cell count BCC.

The device performs ADC conversion on the differential cell voltages and currents. It is capable of very accurate battery charge coulomb counting and battery temperature measurements. Additionally, it communicates with a Flight Management Unit (FMU) through UAVCAN and/or an SMBus.

To use this BMS772 kit, you will need:

Additional items needed

• LiPo battery pack

  • 3S to 6S with cell balancing connector - Voltage range of 6V to 26V

• Suitable charger for the type of battery

• Soldering iron to configure the board

• External Thermistor temperature sensor with cable and JST-GH 2-pin connector (optional)

• Debugger:

  • Segger J-Link Mini debugger

  • PEMicro universal multilink

  • or other suitable JTAG/SWD debugger

Software tools and sources

• S32 Design Studio for ARM-based MCUs (recommended)

• Alternatively : PX4 or NuttX build environment depending on what code source is used.

• PX4/NuttX board target example code (optional, see Software guide)

Note: The RDDRONE-BMS772 board allows to open the charge circuit when the battery is overcharging , to perform cell balancing and to monitor all cell voltages. Therefore the charger does not need to have a cell terminal connector.