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EV & Battery Systems · Free resource

BMS & Cell Balancing Readiness Checklist

Active and passive balancing, pack sensing, and protection logic — gates before you trust a pack in a vehicle or lab dyno.

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1. Pack & sensing

Cell chemistry, series/parallel topology, and capacity documented
Per-cell or per-module voltage sense accuracy validated vs. meter
Current sense (shunt / Hall) calibrated across charge and discharge
Temperature sensors placed at hot spots — not only pack exterior

2. Protection logic

OV / UV / OT / UT / OC thresholds set with hysteresis — not chatter
Contactor / FET open path tested under fault injection
Precharge circuit (if present) verified before main close
Isolation / insulation monitoring in scope for HV packs

3. Balancing strategy

Passive bleed: power, duty, and thermal rise measured at max imbalance
Active balance: transfer efficiency and worst-case time-to-balance estimated
Balance enable window defined (SOC range, charge only, etc.)
Imbalance abort criteria if delta-V grows under load

4. Validation

MATLAB/Simulink or equivalent model matches measured RC / OCV behavior
Charge–discharge cycle logs archived with firmware version
Fault injection: open wire, shorted sense, stuck balance FET
Handoff: BMS firmware hash + config stored with pack serial

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