An open-hardware and low-cost maintenance tool for light-electric-vehicle batteries

The large increment expected in the diffusion of light-electric-vehicles will raise several issues that must be addressed to cope with this trend, including battery diagnostic and maintenance services. The battery system is the most expensive part in the majority of the e-mobility devices. Therefore, battery manufacturers tend to reduce the battery cost by using simple battery management systems that provide only basic safety features. Possible advanced functionalities are not implemented and the battery may lose performance during its use. Widely spread maintenance centers are thus required to support the mobility electrification process, but their diffusion is limited by the high cost of professional battery characterization instruments. This work proposes an open-hardware low-cost battery maintenance tool architecture that can be used with common laboratory instruments. The tool is based on a relay-matrix and a battery monitor integrated circuit. It is able to completely characterize and optimize the state of a battery independently of the battery management system and also gives a figure of the individual aging of the battery cells. The work shows the architecture and the experimental validation of a 16-cells battery maintenance tool prototype. The results demonstrate that utilizing the tool brings the battery in the best possible state and identifies the degradation of the cells in terms of capacity and resistance.