Current Limiting Circuit for 16S LFP Battery Pack – IC Recommendation

DC-DC Power Converters
1

Hello MPS Team,

We are currently working on adding a current-limiting circuit to our 16S LFP battery pack and would appreciate the community’s technical guidance in selecting a suitable TI solution.

Application Requirements

  • Battery Configuration: 16S LFP

  • Maximum Charging Current: 100 A

  • Current-Limiting Condition: When the pack voltage reaches 54 V, the charging current should be limited to approximately 10 A.

  • Control: Standalone solution with MCU-based ON/OFF control

  • Adjustable Current-Limit Range: 3–20 A, allowing the same design to be used for different current-limit requirements

  • Input Voltage Range: 20–120 V

  • Maximum Target Current: 30 A

    • Our initial design target is around 10 A, but we would like the architecture to support higher current levels in future revisions.

  • Package Requirement: Non-BGA package preferred

  • Target BOM Cost: < $10 at a production volume of approximately 1,000–5,000 units

Devices Currently Under Evaluation

Based on our initial evaluation, we have identified the following devices as potential options:

  • MP9931

  • MP2908A

However, we are open to considering other MPS devices or alternative architectures that may be better suited to our requirements.

We would particularly appreciate guidance on:

  1. The most suitable MPS IC/architecture for implementing this current-limiting function.

  2. Whether the above devices can meet the 20–120 V input range and 3–20 A adjustable current-limit requirement.

  3. A recommended power-stage topology for achieving the required current limiting with good efficiency and thermal performance.

  4. Recommended methods for implementing MCU-based ON/OFF control.

  5. Any relevant TI reference designs, evaluation modules, application notes, or existing reference circuits that we can use as a starting point.

  6. Recommendations for achieving the target BOM cost while maintaining adequate reliability for a battery application.

Our goal is to develop a compact, cost-effective, and scalable solution that can initially support approximately 10 A and potentially scale to 30 A in future versions.

We would greatly appreciate any recommendations or feedback from the MPS community that could help us select the right device and architecture.

Thank you in advance for your support.

Regards,
Santu R