Join us for our final piece of our BMS Series! In this article we’ll delve into the BMS certification process & the step-by-step systematic approach we use at Acculon to develop certifiable products that meet the stringent demands of safety standards.
Contact: Betsy Barry
Communication Manager
706.206.7271
betsy.barry@acculonenergy.com
Acculon Energy’s product development is process-driven and prioritizes safety. Our BMS is no exception. Our commitment to safety ensures that our BMS is reliable and adheres to the highest safety standards–safety standards that guide our design and development, every step of the way.
ISO 13849 is a globally recognized standard that outlines the requirements for functional safety of safety-related components of control systems. For our BMS, this standard ensures that the system can reliably detect and mitigate potential hazards, such as overcharging, over-discharging, and thermal runaway.
The Certification Process
1. Risk Assessment and Safety Requirements Specification (SRS)
The process is initiated by conducting a thorough risk assessment and pinpointing potential hazards in the BMS operation. This analysis evaluates both the severity of potential incidents and the likelihood of occurrence, enabling clearly defined safety requirements, which then leads to developing an SRS that details said safety requirements.
2. Designing the System Architecture
Our team develops a BMS architecture that integrates both hardware and software components and is capable of meeting the required Safety Integrity Level (SIL). Fault-tolerant mechanisms are implemented to ensure system reliability, which in turn ensures that the architecture itself supports safe, optimal operations.
3. Hardware Design and Verification
Hardware design is a cornerstone of BMS safety. We carefully select and design components like microcontrollers, sensors, and power electronics to accommodate system requirements. Hardware Failure Mode and Effects Analysis (FMEA) are conducted to identify potential failures, which guide the implementation of fail-safe mechanisms and redundancy that will reduce the chance of single-point failures. The hardware design is verified through simulations, testing, and a range of other formal verification methods.
4. Software Design and Verification
As with everything we do, software development at Acculon is conducted within a functional safety framework and according to coding standards. Every line of code undergoes a software FMEA to identify potential failures. Software design verification entails rigorous testing at multiple levels: unit testing, integration testing, and system testing.
To ensure the safety & reliability of our battery management systems (BMS) while also achieving robust safety certification, we at Acculon emphasize a process-driven approach prioritize the foundational aspects of safety functionality, which are carefully scoped, designed, & thoroughly tested throughout the product development cycle.
5. Safety-Related Control Functions (SRCFs)
Safety-related control functions, or SRCFs, are identified and defined with respect to meeting required performance levels based on a risk assessment. SRCFs are designed and implemented, forming the backbone of a safe and reliable BMS.
6. Validation and Verification
Extensive testing is conducted to validate the BMS against the safety requirements while verifying the system’s ability to detect and respond to faults. Ongoing compliance is evaluated by performing various safety lifecycle management processes, which lead up to the actual certification in earnest.
7. Certification Process
Achieving ISO 13849 certification involves collaboration with a certified 3rd-party organization. After an accredited certification body is selected, comprehensive documentation is submitted, including the SRS, design documents, test reports, and other verification artifacts. The documentation serves as the foundation for the rigorous audit process, which also includes on-site inspections to verify adherence to safety protocols. Any non-conformities identified during the audit are addressed promptly to ensure full compliance. Once all of the requirements have been met, then the ISO 13849 certification is awarded
Key Considerations for BMS Certification
Achieving ISO 13849 certification requires attention to various critical factors:
- Component Reliability: Using components with proven safety records and certifications.
- Redundancy and Fail-Safe Designs: Minimizing risk through redundancy and intelligent fail-safe systems.
- Rigorous Testing: A comprehensive testing regime ensures all components and subsystems meet the required performance levels.
- Thorough Documentation: Detailed records support audits and provide a foundation for continuous improvement.
- Lifecycle Management: Safety doesn’t end with certification; ongoing monitoring and updates keep the system compliant with evolving standards and requirements.
Safety is a process. At Acculon Energy, we integrate it into our operations and product development, which translates to our BMS remaining at the forefront of safety and reliability. ISO 13849 certification is not just a milestone—it’s a testament to our unwavering dedication to protecting lives and advancing energy technology responsibly.
By partnering with certified organizations and maintaining an unwavering focus on safety, Acculon Energy sets a benchmark in the development of secure, high-performing Battery Management Systems.