Sistema de gerenciamento de baterias para Aplicações em segunda vida considerando diferentes arranjos de baterias do tipo ZEBRA

Abstract

The current energy scenario demands sustainable solutions for the reuse of electric vehicle batteries and the development of stationary applications for systemic energy generation and distribution services. In this context, the objective of this research was to design and validate the software for BMS capable of adapting to different topologies of storage systems using second-life batteries. To this end, a modular architecture was adopted, based on the FreeRTOS real-time operating system, with a centralized data structure that allows the dynamic reconfiguration of operating parameters from the Modbus RTU and CANopen protocols without the need to reprogram the device. The experimental validation involved tests of communication, protection, temperature control, insulation fault detection and evaluation of the accuracy of voltage and current measurements, all performed on the bench. Additionally, active balancing modules were developed and tested with ZEBRA batteries and lithium batteries, in which the technical feasibility of the solution was demonstrated, evidencing the ability of the BMS to operate with different battery technologies. The versatility of the system was also proven by its application in several projects at Itaipu Parquetec, including emergency energy storage initiatives, residential energy backup or microgrids for green hydrogen production. The developed software could be applied to two versions of the flexible BMS hardware: the BMSIoT, with multiple string monitoring capabilities and IoT connectivity, and the BMS-1S, a more compact solution designed for monitoring a single string; in addition, the same software model was used in the design of a BMS for lithium batteries. This work represents a significant contribution to enabling the reuse of ZEBRA and other second-life batteries, offering a valuable tool for research and development of new applications.