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BMS Failure Mode Data Collection Thread

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I have had the following failure modes in my battery BMS:

Internal Current Limiter (FETs) let out magic smoke
1
3%
Cell tap wires fatigued/broke
4
10%
Cell tap connector failure (wear, crimp failure, or went resistive)
3
8%
Power lead connector failure (wear, crimp failure or went resistive)
2
5%
BMS failed to catch undervoltage condition on one or more cells
3
8%
BMS failed and overvoltaged one or more cells
2
5%
BMS discharged and ruined pack in storage
6
15%
Internal short in high current leads on or near PCB
1
3%
Internal short/open circuit on PCB
3
8%
Water/moisture damage to PCB/Components
1
3%
Component failure on PCB (note in post)
8
20%
BMS interface failure with charger
1
3%
BMS interface failure with controller
0
No votes
Internal fuse failed/blew
0
No votes
It just quit working and I don't know why
4
10%
Other (explain in post)
1
3%
 
Total votes : 40

Re: BMS Failure Mode Data Collection Thread

Postby jondoh » Tue Oct 26, 2010 10:00 am

Having some experience with reliability testing, I can say the heat and especially heat cycling contributes much to electronic component failure. Electric bikes have thermal cycling, vibration and moisture. This is a tough environment.
My builds at www.JDOBikes.com
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Re: BMS Failure Mode Data Collection Thread

Postby Alan B » Tue Oct 26, 2010 12:32 pm

I just wanted to thank folks for contributing to this thread. I especially get more out of the detailed descriptions of the situation, the report of what happened, and any details that are available.

There are a variety of different things we might do to improve on the reliability of BMS systems, and understanding the failures in some detail is really helpful in evaluating different solutions.
-- Alan W6AKB Cromotored FS GreyBorg, Novara MTB 9C, eBikeE Bent BMC, myEbikeWeb and Thanks to Justin at ebikes.ca for rescuing this forum!
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Re: BMS Failure Mode Data Collection Thread

Postby el_walto » Tue Oct 26, 2010 12:59 pm

I have bought three ping batteries. I have not had a BMS Fail.
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