As a leader in the interconnection industry, Amphenol insists on forging ahead and pioneering technological innovation. To achieve this, we vigorously develop advanced interconnect solutions to support the various components within electric vehicles. With the increasing number of cars on the road, which also brings serious pollution, EV electric vehicles have undoubtedly become a better alternative, which helps to create a more environmentally friendly and safe way to travel.

As a core component of an electric vehicle, a battery management system (BMS) is dedicated to controlling and managing battery performance. In a variety of different application environments, the BMS can support locking chargers, stable performance, and improved battery life. The system continuously monitors lithium-ion battery packs during charging and discharging and performs balancing management of cells within the pack to optimize battery and EV performance. The BMS also supports many other functions, such as checking for faults and determining available energy and remaining service life.

The BMS can monitor battery voltage and temperature, and limit power input and output, preventing the battery from overheating and overcharging. In addition, by communicating with multiple parties, it can also isolate the battery pack from the power source and load when necessary. During charging and discharging, the BMS continuously evaluates the state of charge (SoC) and state of health (SoH) of the battery pack. Today’s advanced BMSs can also calculate the remaining useful life (RUL) of batteries, perform battery balancing management, monitor, and store historical data.

BMS Architecture

BMS usually adopts a centralized and modular architecture. The centralized architecture consists of a main BMS and some smaller remote units. In a modular or distributed architecture, remote units are connected in parallel with the main system and are responsible for controlling individual units within the battery pack. In some cases, they are daisy-chained in series, providing higher voltages and increasing capacity. This approach helps protect the main BMS from damage due to rapid voltage changes. In such emergencies, the connection between the smaller unit and the main BMS is isolated.

FPC-to-Board Connector

Automotive grade FPC-to-Board connector

Amphenol offers a wide range of interconnect solutions designed to improve the reliability and performance of battery management systems. The FlexLock FPC-to-Board connector is an important solution designed for BMS. This compact automotive-grade connector complies with the USCAR-T2V2 specification; it has a current carrying capacity of 3A per loop, and is available in 2.54mm and 3.20mm pitch sizes, supporting 10 to 30 pin positions and 10 to 26 pin positions, respectively. This series of connectors features reflow tinned contacts for ultra-low mating force. The hold-down function increases plate holding force and is highly vibration-resistant, making it an ideal connection solution for automotive applications such as BMS. Terminal Locking Tabs (TPA) ensure proper terminal insertion position and retention, while Connector Secondary Locking (CPA) ensures proper mating and locking.

Reviewing Editor: Peng Jing

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