Extending Battery Lifespan UP TO 52 % with a Smart BMS Algorithm

A long battery lifetime can only be achieved when all cells within a battery system perform almost identically. This is precisely where ETA-Leveling comes in—a battery management system (BMS) algorithm that compensates for differences in cell efficiency at an early stage, significantly extending the overall lifespan of battery systems.

PEM Motion and BENNING CMS Technology have jointly developed a Matlab-based software model that enables seamless integration of this algorithm into industrial BMS solutions—without the need for additional hardware, lengthy development cycles, or modifications to safety-critical system components.

The Challenge: Uneven Aging Across Battery Cells

Battery systems never age uniformly. Even during the first charging cycles, minimal differences in the efficiency of individual cells emerge caused by manufacturing tolerances, temperature variations, or uneven loads imposed by BMS hardware. Over time, these discrepancies lead to a growing divergence in the State of Charge (SoC) between cells. Conventional balancing methods can only partially correct this process. The result: premature cell aging, reduced usable capacity, and increased service or replacement costs.

The Solution: ETA-Leveling Targets the Root Cause

ETA-Leveling intervenes earlier and more effectively by addressing the actual physical cause of cell drift—the individual efficiencies of each cell. By compensating for these variations at the system level, the algorithm prevents SoC divergence right from the start. “With ETA-Leveling, we ensure that battery cells maintain their performance over many charging cycles. This significantly extends the lifespan of complete battery systems by up to 52%,” emphasizes Frederik Fuchs, Managing Director at Benning CMS Technology. Even for batteries that no longer meet automotive standards, the algorithm can realign cell performance, reduce capacity losses, and make second-life applications economically attractive.

Scalable Innovation for Industry Use

One of PEM Motion’s core missions is to make innovative technologies industrial-ready—quickly, safely, and efficiently. Therefore, ETA-Leveling was designed to be as accessible and practical as possible for BMS manufacturers.

“Innovations should not remain theoretical concepts with limited applicability. They must deliver practical, scalable, and economic value to the industry,” explains Carl Richter, Director at PEM Motion.

In collaboration with Benning, PEM Motion has developed a Matlab-based software model that allows ETA-Leveling to be integrated quickly and efficiently into industrial BMS solutions without hardware modifications, additional development time, or interference with safety-critical system architectures.

Powerful Simulation and Validation Capabilities

Beyond direct implementation, the software model also provides a robust simulation environment. This allows BMS manufacturers and battery developers to test the algorithm under realistic conditions, assess its impact on lifetime, cell balance, and capacity, and make decisions based on reliable, data-driven insights.

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Unlock the Full Potential of Your Battery Systems

With deep expertise in battery management system development, customization, and optimization, PEM Motion supports companies in designing intelligent, high-performance BMS architectures—from concept and modeling to validation and industrial integration. Find more information on our BMS Solutions Page.

If you are looking to enhance the efficiency and longevity of your battery systems or explore how ETA-Leveling can be integrated into your BMS solutions, get in touch with our experts at PEM Motion to discuss your individual development needs.