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In every electric vehicle (EV), the Battery Management System (BMS) plays a critical role in ensuring safety, performance, and longevity of the battery pack. Acting as the “brain” of the battery, the BMS continuously monitors, protects, and optimises battery operation under varying conditions.
As part of our E-Mobility Solutions, this week we focus on the Battery Management System block within the EV architecture, highlighting how key components come together to support reliable EV performance.
Battery Management System (BMS) in Electric Vehicles
The BMS is responsible for:
Monitoring cell voltage, current, and temperature
Balancing battery cells for consistent performance
Protecting against overcharge, over-discharge, and thermal runaway
Supporting energy efficiency and battery lifespan
This makes the BMS a mission-critical subsystem in EV platforms, from passenger vehicles to commercial and industrial electric mobility solutions.
BMS environments demand components that can withstand:
High current and power density
Thermal stress and temperature fluctuations
Vibration and mechanical shock
Long operational lifecycles with minimal maintenance
Component selection within the BMS directly impacts system reliability, safety compliance, and overall vehicle performance.
Designing a robust BMS requires addressing several engineering challenges:
Ensuring stable, low-resistance electrical connections
Managing heat in compact, high-power designs
Maintaining signal integrity in harsh operating environments
Achieving long-term reliability under continuous cycling
Through our technology partners, we support BMS design with proven, automotive-ready solutions:
🔹 Harwin Asia– Press-Fit Terminals (MMi)
Provide reliable, vibration-resistant electrical connections without soldering, ideal for high-reliability BMS assemblies.
🔹 CAP-XX – Cylindrical Supercapacitors
Deliver high power density and stability, supporting peak power demands and energy buffering within the BMS.
🔹 SGC Circuits – Heavy Copper / Rigid-Flex PCBs
Enable excellent thermal performance and mechanical reliability, even in harsh EV operating environments.
Together, these solutions help engineers build safer, more efficient, and more durable Battery Management Systems.
This downloadable brief focuses on the Battery Management System (BMS) section of our EV system block diagram, extracted from our official E-Mobility solutions catalogue.
It provides a clear overview of how the BMS fits within the EV architecture, along with recommended components designed for reliability, power stability, and harsh operating environments.
👉 Complete the short form to download the EV BMS Application Brief (PDF).
This download includes the EV system block diagram page with BMS highlighted.
The Battery Management System is truly the heart of every EV — protecting the battery, maximising performance, and ensuring long-term reliability. By combining high-quality interconnects, advanced energy storage components, and robust PCB technologies, iConnexion supports EV designers in developing next-generation BMS solutions.
