At CES 2023, the engineering team at Munro explored Texas Instruments’ cutting-edge battery management system (BMS) technology. This suite of silicon-based innovations works to maximize driving range, enhance charging, lower costs, and improve safety for electric vehicles. For automotive engineers, EV enthusiasts, and industry investors, TI’s approach shows how precision electronics can directly boost performance, increase efficiency, and strengthen safety.
The Mission: Range, Affordability, Safety
Mark Karanam from Texas Instruments outlined the company’s fourfold mission:
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Maximize driving range through highly accurate battery monitoring.
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Enhance charging experiences by enabling precise state-of-charge estimates.
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Lower EV costs by supporting efficient designs and lithium iron phosphate (LFP) battery chemistries.
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Increase safety via advanced contactor and pyrotechnic element control.
TI builds this mission on its high-voltage BMS architecture. The system combines critical monitoring, control, and safety functions into one comprehensive electronics platform. This integration streamlines design and strengthens overall system performance.
Inside the Silicon Suite
TI’s CES display featured every major BMS silicon device in its lineup. Components included:
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Battery cell monitors with industry-leading 1 mV voltage measurement accuracy.
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Pack monitors tracking current and isolation resistance.
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Microcontrollers for real-time system management.
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Contactor drivers for safe high-voltage switching.
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Pyro element drivers for rapid battery disconnection in emergencies.
For engineers, the 1 mV accuracy goes beyond a simple specification. It delivers a transformative capability. With greater precision in cell voltage measurement, state-of-charge calculations become far more accurate. As a result, OEMs can extract every usable ampere-hour from a battery pack while still protecting safety margins.
Hardware-in-the-Loop Testing
Mouli Nikunz Karanam demonstrated TI’s hardware-in-the-loop (HIL) simulator, which models real lithium-ion cell behavior in dynamic driving conditions. Using the Worldwide Harmonized Light Vehicle Test Procedure (WLTP) drive cycle, the simulator generates voltage and current profiles that replicate real-world load patterns.
During the demo, TI’s system measured cell voltages with unprecedented accuracy. This level of precision allows designers to:
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Increase usable capacity without oversizing battery packs.
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Reduce manufacturing costs by potentially using smaller packs.
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Improve range estimates for drivers, enhancing confidence in EV travel.
Functional Safety at the Highest Level
TI’s BMS devices are designed to meet ASIL D, the highest automotive functional safety rating. This includes both monitoring and control functions:
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Safe opening of high-voltage contactors in the event of faults.
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Triggering pyrotechnic disconnects during severe incidents.
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Fault detection for overvoltage, undervoltage, overcurrent, and coolant leakage.
In a live fault simulation, an overvoltage threshold was set to 4.2 V per cell. Once exceeded, the system instantly detected the condition and opened the contactors — disconnecting the pack from the high-voltage bus to prevent damage or safety hazards.
Transitioning from Wired to Wireless BMS
While the initial demonstration focused on a wired BMS configuration, TI also showcased its wireless BMS technology. This approach eliminates the need for complex wiring harnesses between battery modules, reducing weight and assembly complexity while improving serviceability.
To illustrate, TI monitored the battery pack of a remote-controlled (RC) car in real time. Voltage and temperature data were transmitted wirelessly to a central receiver. The system also included crash detection — triggering a simulated pyro disconnect when the RC car collided with an obstacle.
Why Accuracy Matters for Range and Cost
For OEMs, the ability to measure cell voltages with 1 mV accuracy has both performance and economic implications.
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Performance: Accurate state-of-charge data ensures drivers get maximum possible range from every charge cycle.
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Economic: Smaller packs can deliver comparable range to larger, less precisely managed packs — lowering material and production costs.
As EV adoption accelerates, these dual benefits position TI’s BMS as a critical enabler of competitive, efficient, and safe vehicles.
Enabling the Shift to LFP Batteries
TI’s system supports lithium iron phosphate (LFP) chemistry, known for its lower cost, longer cycle life, and enhanced thermal stability compared to traditional lithium-ion chemistries. However, LFP packs have a flatter voltage curve, making accurate measurement even more critical. TI’s precision monitoring addresses this challenge head-on.
Practical Takeaways for Engineers and OEMs
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Adopt high-accuracy monitoring to maximize range without increasing battery size.
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Integrate ASIL D-rated components for robust functional safety compliance.
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Leverage wireless BMS to reduce wiring complexity, weight, and assembly time.
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Use HIL simulation to validate designs under realistic drive cycles before production.
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Support LFP chemistries with measurement systems capable of distinguishing small voltage variations.
Conclusion: Precision as a Competitive Edge
Texas Instruments’ CES 2023 demonstration wasn’t just a showcase — it was a blueprint for the next generation of electric vehicle battery management. By combining unmatched measurement accuracy, comprehensive functional safety, and innovative wireless capabilities, TI delivers a solution that benefits OEMs, suppliers, and end users alike.
For automakers navigating the balance between performance, cost, and safety, TI’s BMS technology offers a compelling path forward. Whether optimizing for range, streamlining manufacturing, or supporting safer EV operation, precision electronics remain at the heart of the industry’s evolution.
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