4680 Cell Module Design with Dukosi Cell Monitoring System (DKCMS®)
The Dukosi Cell Monitoring System (DKCMS®) supports larger-format cylindrical cells, such as 4680-class cells, which are transforming the electric vehicle (EV) industry. These cells offer an ideal combination of increased energy density, power output, superior thermal management, increased robustness, and attractive cost per kWh. This momentum is reinforced by commitments from some of the world’s largest cell manufacturers and automotive OEMs1.
DKCMS provides unparalleled flexibility and scalability across all cell formats, sizes, and chemistries. It simplifies battery architecture, reducing design, validation, and manufacturing costs, and is ready for battery designers embracing larger cylindrical cells, including 4680-class formats.
An example of a 6S3P configuration module using 4680 cells with top-mounted Cell Monitors, and lid-integrated bus antenna for communication to the BMS host processor
Dukosi Cell Monitor Integration
As an all-in-one smart cell chip that includes voltage, temperature and sensor connectivity, data processing, storage, and communications, the Dukosi Cell Monitor is typically installed one-per-cell or cell-group on a highly compact PCB (flexible or rigid). The demonstrator shown uses 4680 cylindrical cells, with a single large PCB substrate, tabs laser welded connection to module busbars, integrated into CCS tray compatible for heat sinking. The cell monitors are positioned closely to the cells they oversee, minimizing sense wire lengths to ensure the most accurate voltage readings possible. It has been designed for fully automated module manufacture.
A close-up of the PCB with Cell Monitors installed, each covering a small series of cells
Simple, Robust Communications with Layout Flexibility
DKCMS’ single bus antenna can be routed along the most efficient path across multiple modules, which may extend up to 10 metres and connect more than 200 Cell Monitors, supporting even the largest battery designs.
Cell Monitor antennas can be configured either in line with or orthogonal to the bus antenna, providing additional design flexibility. The antenna may be secured directly to the Cell Monitor PCB using fixings or integrated into the battery module lid or housing, depending on design and manufacturing requirements. In this demonstrator example, the bus antenna is integrated directly into the module lid, separating the installation step to streamline manufacturing and enabling this typically labor-intensive process to be automated.
More Temperature Sensing
Each Cell Monitor includes an integrated temperature sensor and supports up to two additional thermistors. This enables broader temperature monitoring across cell groups and at critical locations within a cell module. During battery development, this capability helps identify hot spots in prototype designs, while in production batteries it can generate comprehensive internal temperature maps to meet the demanding requirements of safety-critical and reliability-critical applications.
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- Cell manufacturers include: BAK, BYD, CATL, EVE Energy, LG Energy Solution, Lishen, Panasonic, Samsung SDI, SK On, Sunwoda, and Tesla ↩︎