Power line communication (PLC) within future smart batteries facilitates the communication of high fidelity sensor data between smart cells and external systems, with application areas including intelligent vehicles and smart grids. This interconnected PLC system of smart cells will enhance cell utilisation and safety through cell-to-cell coordination at a system level, leveraging the existing bus bar within the battery and eliminating the need for additional wire harnesses. This paper studies the performance of a PLC system operating at carrier frequencies of 10MHz to 6GHz within four distinct configurations of lithium-ion batteries. This assessment focuses on changes in scattering parameters and data transmission error ratios. Furthermore, quadrature amplitude modulation (QAM) orders of up to 1024 are investigated for their viability within such environments. The results indicate that the addition of cells in parallel increases error ratios with high-order QAM, and that this effect varies substantially with carrier frequency. Using QAM increases data throughput, allowing for data transfers within large-scale battery systems without PLC bus bandwidth saturation. A prospective centre frequency of 3650MHz allows for a wide bandwidth of 300MHz and 1024-QAM with little signal attenuation and data error. At this frequency, the need for signal repeaters and higher signal output power is reduced. These results are used to determine the most suitable arrangement of cells within a smart battery with consideration of the PLC performance. The preliminary performance of a large-scale battery system with PLC in-situ could be derived from the findings in this research based upon the four battery configurations tested.
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