IoT-Enabled Smart Battery Management System

Author

V.G. Umale , Ashray Babhare , Kashish Gajbhiye, Pranjal Kale, Riya Narnaware, Vaishnavi Thakare

Abstract

 Most battery management systems (BMS) in electric vehicles (EVs) reach the user only as a single pack-level number, which hides what individual cells are doing and leaves the driver with little warning before a thermal event. This paper presents the design and prototype testing of a low-cost, IoT-enabled BMS built around an ESP32 controller for a 4S lithium-ion pack (14.8 V nominal, 16.8 V maximum). The prototype measures the voltage at every cell tap through resistor dividers, records load current and power with an INA219 sensor, and tracks three temperature points with DS18B20 probes. A four-mode thermal strategy (normal, fan, max cool and shutdown) switches a fan, a Peltier module and a protection relay according to user-configurable temperature limits, and a buzzer signals the shutdown state. Readings are shown on a local 2.8-inch touchscreen and on a web dashboard served by the ESP32 itself over its own Wi-Fi access point, together with an event log and settings that survive a restart. A brushless DC motor driven through an electronic speed controller acts as an adjustable load during testing. Bench tests covering fourteen functions confirmed that measurement, cooling escalation, relay cut-off and both user interfaces behaved as designed. The paper also states plainly what the prototype does not yet do, mainly capacity-based State of Health estimation, coulomb counting and cell balancing, and outlines how these can be added.

Keywords

battery management system, electric vehicle, ESP32, lithium-ion battery, thermal management, Peltier cooling, cell monitoring, IoT dashboard.

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References

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