BMS Module — Enclosure View
BMS PCB Inside Housing
BMS Hardware Module
BMS PCB — Production Rev
Analogue Front-End (AFE) Board
EmbDes CAN Data Logger
TESAS engineers bespoke Battery Management Systems from ground up — analogue front-end (AFE) hardware, embedded firmware with advanced algorithms, and cloud-connected diagnostics for EV packs, BESS racks, and industrial battery applications.
Kalman-filter and ML-based State of Charge (SoC), State of Health (SoH), State of Power (SoP), and Remaining Useful Life (RUL) estimation — accurate to ±1% across temperature and ageing.
Active and passive balancing topologies. Active balancing transfers energy between cells at >90% efficiency, extending pack life by 15–25% compared to passive-only designs.
Multi-level protection: overvoltage, undervoltage, overcurrent, short-circuit, overtemperature, under-temperature, and isolation fault — all hardware + firmware redundant.
Closed-loop thermal control of active cooling/heating systems — cell-level NTC monitoring, predictive pre-heating for cold starts, and thermal runway early detection.
CAN 2.0B (J1939 / CANopen), Modbus RTU/TCP, RS485, SMBus, I²C, UART, and LTE/Wi-Fi for cloud telemetry. Custom protocol support on request.
Real-time data logging to AWS/Azure, over-the-air (OTA) firmware updates, and a web dashboard for fleet-wide SoH trending and predictive maintenance alerts.
Our hardware team designs multi-layer PCBs from schematic to Gerber — integrating AFE ICs (Texas Instruments BQ series, Analog Devices LTC series), isolated gate drivers, current-sense amplifiers, and isolated communication transceivers.
| Capability | Detail |
|---|---|
| Cell Count | Up to 256S per BMS master |
| Voltage Measurement | ±1 mV accuracy, 16-bit ADC |
| Current Sensing | Hall-effect + shunt, ±0.5% FS |
| Temperature Channels | Up to 32 NTC inputs per unit |
| Isolation | 5 kV reinforced, CMRR >100 dB |
| Processor | ARM Cortex-M4/M7, AUTOSAR-ready |
| Operating Temp | −40°C to +85°C |
| Form Factor | Custom PCB or DIN rail module |
Written in C/C++ with MISRA-C compliance for safety-critical applications. Our firmware stack includes RTOS scheduling, model-based SoX algorithms, fault state machines, and CAN stack.
Static analysis with PC-lint, LDRA, and Polyspace — meets ISO 26262 ASIL-B for automotive BMS.
Simulink / MATLAB algorithm prototyping with auto-code generation for rapid iteration and validation.
Hardware-in-Loop testing with dSPACE or Vector CANoe — validate BMS behaviour against real cell emulation before physical prototype.
Secure OTA with code signing, rollback protection, and staged deployment across deployed fleets.
2W, 3W, 4W, and commercial EV battery packs. AIS 156 Phase 2 compliant.
High-voltage BESS racks (up to 1500V) with parallel string management.
Low-power BMS for off-grid solar storage in agriculture and rural microgrids.
IEC 62133-certified BMS for medical-grade battery backup systems.
Share your cell chemistry, voltage range, and target certification — our BMS engineers will respond with a design approach within 48 hours.