To use lithium-iron-phosphate battery packs in the supply systems of any electric mining equipment and/or machines, the required conditions of work safety must be met. This applies in particular to coal mines endangered by fire and/or explosion. To meet the spark-safety conditions, the cells (together with the battery management system—BMS) must be isolated from the influence of the environment, and therefore placed in special fire-tight housings. This significantly degrades the heat dissipation, thus affecting the operating conditions of the cell-packs. Therefore, their usage without the so-called BMS is not recommended, as shown in the authors’ preliminary research. In practice, various BMS are used, most often with the so-called passive balancing. However, their application in mines is uncertain, due to the effect of heating under operation. When it comes to active BMS, they usually possess a quite complex structure and hence, are relatively expensive. Therefore, the authors conducted research for two specially developed active and one commercial passive BMS cooperating with selected lithium-iron-phosphate (LiFePO₄) batteries when used in a suspended mining vehicle type PCA-1. The tests were carried out under environmental temperatures ranging from +5 °C to +60 °C. The effect of mismatching (12.5% to 37.5% of total cells number) of the cell parameters on the temperature distribution and voltage fading at the terminals of individual cells was checked. As a result of the investigations, the practical usefulness of the developed active BMS was determined, enabling the extension of the lithium-iron-phosphate battery life under onerous mine conditions, for a single recharge, which is a novelty. On the basis of the obtained results, appropriate practical conclusions were formulated.

The article presents and discusses the results of research on hazard, especially temperature, for selected lithium-ion-phosphate cells operated in accordance with the manufacturer’s recommendations but used under onerous mining conditions. This applies to the performance of cells in battery sets without the application of any management system (BMS). On the basis of the obtained test results, first of all, the influence of the value of the charging current of cells and the ambient temperature for both free and deteriorated heat exchange, appropriate conclusions and practical recommendations were formulated. This applies especially to threats in the case of random, cyclic, minor overloading, and discharging of the cells.

The article presents methods for balancing the cells of batteries made in lithium-ion technology. They have many advantages over the traditional lead-acid batteries. The most important advantages include fast charging, high energy density and power as well as a wider range of operating temperatures. However, they require the use of battery surveillance and management systems (BMS) to increase work safety. One of the most important functions of such a system is the method of balancing, i.e. charge equalization of each cell. This article explains the purpose of balancing, presents the test results, describes the methods for realization of this process, taking into account the advantages and disadvantages of each of them.

Using lithium batteries to supply electric machinery and/or equipment in underground mines requires an adequate level of security. This is particularly important in coal mines, especially under the threat of methane explosions and/or fire hazards. Lithium battery cells with a BMS should be effectively isolated from the impact of the surrounding mine environment. This can be achieved by storing all battery systems in a certified explosion-proof enclosure (Ex) in accordance with the relevant regulations and standards. Preliminary tests conducted by the authors indicated that use of lithium cells without a BMS in mines is risky and, in practice, unacceptable. BMSs with passive cell balancing are most commonly employed. They allow for the equalization of cell voltages primarily during the charging process. However, the lowest-capacity cell still determines the overall lifetime of a battery. Furthermore, the use of active balancing systems (BMSs) is rare in practice due to their greater complexity and price. Nevertheless, they can significantly extend battery life through the much more efficient redistribution of energy among the cells, including during the discharge process. This article presents the operation of a modified (hybrid) BMS architecture, combining both passive and active balancing methods when employed for the selected suspended mine vehicle. It enables more safe and more effective charging process, as well as discharging process, which results in the longer time of operation of lithium battery packs, for one charge. This system is intended for use in mining machinery and equipment, as well as in selected energy storage systems powered by lithium-based battery modules.