Overview
A high-current lithium-ion battery management system designed for industrial drone platforms where power density, discharge performance, and system reliability under vibration and temperature stress are critical.
- Multi-cell series-parallel lithium-ion pack management up to 50 V with peak discharge currents exceeding 100 A.
- Real-time cell balancing, state of charge (SoC), state of health (SoH) monitoring, and thermal protection.
- CAN bus communication with the flight controller for high-rate telemetry and safe landing coordination.
- High-side gate drive circuitry and precise current sense amplifier with sub-microsecond overcurrent protection.
- Optimised thermal design with advanced copper pours and thermal via arrays beneath the primary FETs.
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Challenge
Designing a battery management system that handles continuous currents of up to 120 A while maintaining cell monitoring precision under heavy load noise.
Solution
Designed a multi-phase active cell balancing circuit, low-side shunt measurement, and isolated SPI battery monitor daisy chain.
Outcome
Successfully reduced thermal footprint by 35% and increased total drone flight time by 12%.