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MEGATRON - Large Capacity Lithium Battery Management System

BATKON prepared "MEGATRON" BESS systems , with the R&D and P&D studies carried out by BATKON on the Lithium Battery Energy Storage System (Li BESS), which is the most frequently used type of technologies designed to store large amounts of electrical energy.

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Our basic approach to BESS was to make the system "Modular" and to reach the desired DC voltage and desired Wh capacities by adding and removing these modules. In this context, we have equipped our “BMSLion” lithium battery management hardware with special communication and management algorithms, and we have prepared an infrastructure that enables the production of storage systems that can reach from 16 cells to 400 cells and in practice reach 1300 VDC voltages.  

The smallest unit of the system is formed as a box in the LBM (Lithium Battery Module), where up to 16 cells with the desired Ah capacity are monitored with BMU hardware and embedded software. The cell chemistry (LFP, NMC, NCA, LCA, LTO etc.) to be used can vary completely according to the application because BMU can be adapted to any Lithium chemistry as hardware and software.  

We also designed a Master BMS (MSC-Master String Controller)  to coordinate the BMUs controlling the LBM modules and manage the high voltage storage system, and created the protocol for this hardware to communicate with the Slave BMUs in the LBMs via isolated CANBus. In this way, the Master BMS can take the measured data from all other slave BMU's over CANBus and use it to make decisions about the system.

Typical MEGATRON Array Structure

Master BMS-MSC; OVP (Over voltage protection), UVP (Under voltage protection), OTP (Over temperature protection), OCP (Over current protection during Charge/Discharge) expected from a Lithium BMS as it instantly learns the voltages and temperature values of all cells on the array ) can operate all protection algorithms. Master BMS can also control the contactors connected in series to the cell array (String) it controls, and can cut the current flow in the direction of charge and discharge when necessary. At the same time, by sensitively reading the string current with the “hall effect” current sensor; In addition to the overcurrent protection function, it can also calculate the current capacity of the array in Ah.

Multiple cell lines can be used in a MEGATRON system. This is a necessary feature for the LBM modules to be ergonomically lifted off the ground and placed in racks. Because when you try to put 15-16 cells larger than 150 Ah and put them in a single metal box, the weight of the box can exceed the limits of ergonomics. For this reason, it becomes necessary to run more than one array in parallel to reach Megawatt-hour capacities. Considering this at MEGATRON, we planned each series as a maximum of 150 Ah. We have added high voltage power electronics systems called “Power Conversion System – PCS” in the literature, which functions as a “bidirectional rectifier/inverter” with a capacity of 100 kW in front of each array. In this way, for example, for a BESS requiring 1 MW of power, we have created a structure that will connect 10 strings in parallel on the AC side.  

While our BMS communicate with each other via CANBus, they also manage features such as passive cell balancing and passive module balancing within LBM boxes. In this way, we help to optimize the energy storage capacity of BESS by reducing the voltage and hence the SoC differences between hundreds of series-connected Lithium cells.



In MEGATRON systems with more than one array, we have also developed an EMS module for inter-array coordination and communication of BESS with the outside world. This unit, which also has an LCD screen, communicates with the Master BMS over RS485 MODBUS, gaining knowledge about the entire system and can make basic decisions by analyzing this information. Commands received from SmartGrid cloud servers via EMS are transmitted to MasterBMS, and EMS handles dozens of situations, such as the activation of the arrays at the desired power in the direction of charge or discharge, the equal distribution of power between the arrays, the isolation of the detected array from the system, and the transmission of alarms to the SmartGrid cloud servers.

Our MEGATRON system can be mechanically designed as required. For example, we can produce arrays in the form of classical rack systems. We can also apply mechanical designs in the form of boxes with larger capacity and can be mounted on top of each other, if needed.

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