TIDA-01040

Battery Tester Reference Design for High Current Applications

TIDA-01040

Design files

Overview

Li-Ion battery formation and electrical testing require accurate voltage and current control, usually to better than ±0.05% over the specified temperature range.  This reference design proposes a solution for high-current (up to 50 A) battery tester applications supporting input (bus) voltages from 8 V–16 V and output load (battery) voltages from 0V–5V. The design utilizes an integrated multi-phase bidirectional controller, LM5170, combined with a high precisiondata converters and instrumentation amplifiers to achieve charge and discharge accuracies of 0.01% full scale. To maximize battery capacity and minimize battery formation time, the design uses highly-accurate constant current (CC) and constant voltage (CV) calibration loops with a simplified interface. All key design theories are described guiding users through the part selection process and optimization. Finally, schematic, board layout, hardware testing, and results are also presented.

Features
  • Battery test subsystem with calibration control achieving 0.01% full scale current control accuracy
  • Supports up to 50-A applications with an input voltage (bus) from 8 V–16 V and output load (battery) from 0 V–4.5 V (5 V max)
  • LM5170 bidirectional buck, boost controller
  • Programmable high-precision reference supplied by DAC80004
  • Voltage and current monitoring provided by the ADS131A04 24 bit delta-sigma
  • User friendly control interface

A fully assembled board has been developed for testing and performance validation only, and is not available for sale.

Design files & products

Design files

Download ready-to-use system files to speed your design process.

TIDUE89B.PDF (3976 K)

Reference design overview and verified performance test data

TIDRWJ9.PDF (1255 K)

Detailed schematic diagram for design layout and components

TIDRWK0.PDF (215 K)

Complete listing of design components, reference designators, and manufacturers/part numbers

TIDRWK1.PDF (431 K)

Detailed overview of design layout for component placement

TIDRWK3.ZIP (4178 K)

Files used for 3D models or 2D drawings of IC components

TIDCER0.ZIP (1352 K)

Design file that contains information on physical board layer of design PCB

TIDRWK2.PDF (5830 K)

PCB layer plot file used for generating PCB design layout

Products

Includes TI products in the design and potential alternatives.

Analog switches & muxes

SN74LV4053A-Q1Automotive 5-V, 2:1 (SPDT), 3-channel analog multiplexer

Data sheet document-pdfAcrobat PDF
Arm-based microcontrollers

TM4C1294NCPDT32-bit Arm Cortex-M4F based MCU with 120-MHZ, 1-MB flash, 256-KB RAM, USB, ENET MAC+PHY ;

Data sheet document-pdfAcrobat PDF
Buck-boost & inverting controllers (external switch)

LM51183-75V Wide Vin, Current Mode Non-Synchronous Buck-Boost Controller

Data sheet document-pdfAcrobat PDF open-in-new HTML
Buck-boost & inverting controllers (external switch)

LM5170-Q1Multiphase bidirectional current controller, AEC-Q100 qualified

Data sheet document-pdfAcrobat PDF open-in-new HTML
Charge pumps (inductorless)

LM26641.8-V to 5.5-VIN switched capacitor voltage inverter

Data sheet document-pdfAcrobat PDF open-in-new HTML
ESD & surge protection ICs

TPD4S012Quad 0.8-pF, 5.5-V, ±8-kV ESD protection diode with 15-V tolerant Vbus for USB Interface

Data sheet document-pdfAcrobat PDF open-in-new HTML
Fully differential amplifiers

THS4561Low-power, 60-MHz, wide-supply-range fully differential amplifier

Data sheet document-pdfAcrobat PDF open-in-new HTML
General-purpose op amps

LM6142Dual, 24-V, 17-MHz, low-power operational amplifier

Data sheet document-pdfAcrobat PDF
Instrumentation amplifiers

INA18836-V, Zero-Drift, Rail-to-Rail-Out Instrumentation Amplifier

Data sheet document-pdfAcrobat PDF open-in-new HTML
Inverting buffers & drivers

SN74LVC1G04-Q1Automotive single 1.65-V to 5.5-V inverter

Data sheet document-pdfAcrobat PDF
Linear & low-dropout (LDO) regulators

TPS709150-mA, 30-V, ultra-low-IQ, low-dropout voltage regulator with reverse current protection and enable

Data sheet document-pdfAcrobat PDF open-in-new HTML
Linear & low-dropout (LDO) regulators

TPS717150-mA, high-PSRR, low-IQ, low-dropout voltage regulator with enable

Data sheet document-pdfAcrobat PDF open-in-new HTML
Linear & low-dropout (LDO) regulators

TPS7371-A, ultra-low-dropout voltage regulator with reverse current protection & enable

Data sheet document-pdfAcrobat PDF open-in-new HTML
Precision ADCs (<=10MSPS)

ADS131A0424-bit 128-kSPS 4-channel simultaneous-sampling delta-sigma ADC

Data sheet document-pdfAcrobat PDF open-in-new HTML
Precision DACs (<=10MSPS)

DAC80004Ultra-Small, true 16-bit quad voltage output DAC with 1LSB INL/DNL

Data sheet document-pdfAcrobat PDF open-in-new HTML
Precision op amps (Vos<1mV)

OPA227710µV, 0.1µV/˚C, High-Precision, Low-Power Operational Amplifier

Data sheet document-pdfAcrobat PDF open-in-new HTML
Precision op amps (Vos<1mV)

OPA827Low-noise, high-precision, JFET-input operational amplifier

Data sheet document-pdfAcrobat PDF open-in-new HTML
Precision op amps (Vos<1mV)

TLV07Precision, 36-V, low noise, rail-to-rail output, operational amplifier

Data sheet document-pdfAcrobat PDF open-in-new HTML
Series voltage references

REF50252.5-V, 3-µVpp/V noise, 3-ppm/°C drift precision series voltage reference

Data sheet document-pdfAcrobat PDF open-in-new HTML
Series voltage references

REF50505-V, 3-µVpp/V noise, 3-ppm/°C drift precision series voltage reference

Data sheet document-pdfAcrobat PDF open-in-new HTML
Voltage translating gates

SN74LV1T00Single power supply 2-input POSITIVE NAND gate logic level shifter

Data sheet document-pdfAcrobat PDF
Voltage translating gates

SN74LV1T32Single Power Supply 2-INPUT POSITIVE OR GATE with Logic Level Shifter

Data sheet document-pdfAcrobat PDF

Technical documentation

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Type Title Date
* Design guide Battery Tester Reference Design for High Current Applications (Rev. B) Jul. 18, 2019
Technical article Taking a modular approach to high-precision, high-current battery test equipment Jun. 21, 2019
Technical article Achieving highly accurate full-scale charge and discharge current control for high-cell Li-ion battery-formation testing Aug. 13, 2018

Related design resources

Hardware development

EVALUATION BOARD
LM5170EVM-BIDIR LM5170 48V-12V Bidirectional Converter Evaluation Module USB2ANY USB2ANY interface adapter

Software development

SUPPORT SOFTWARE
DELTASIGMAEVAL-GUI Delta-sigma ADC EvaluaTIon software

Reference designs

REFERENCE DESIGN
PMP15038 50A, 0.05% Current Accuracy Power Reference Design for Battery Test Systems PMP15043 6A, 0.05% Current Accuracy Power Solution for Battery Test Systems Reference Design PMP40182 Bi-Directional Battery Initialization System Power Board Reference Design PMP40280 Bi-Directional Battery Initialization System Control Board Reference Design

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