EV Battery Management System

Off-the-shelf BMS solutions did not meet the space, weight, and performance constraints of a lightweight electric motorcycle. The system required custom circuit design, embedded firmware, and packaging tailored to the vehicle’s form factor while maintaining reliability. ITAR compliance restricted technical data access and required U.S. export control standards for development, component sourcing, and documentation. The BMS needed continuous monitoring of cell voltages, temperatures, and current to prevent overcharging, over-discharging, and thermal events. Cell balancing was required to maintain uniform charge distribution and extend battery life. Data logging capabilities were needed to capture usage patterns, performance metrics, and degradation indicators for predictive maintenance and warranty analysis. Integration with the motorcycle’s propulsion controls, displays, and communication networks was required, providing accurate state-of-charge and state-of-health information.