This is quite the multipart and deep question. You seem to understand the basics but just in case, I’ll recommend this website as a good overview, albeit dated in terms of current ICs and BMS competitors.
http://liionbms.com/php/index.php
Chips
This is dependent on application. For small packs like the one you’ve drawn, there are a wide variety of chips available. For larger packs, Linear (LTC6803) and Maxim (MAX11081) are the two main competing suppliers of BMS solutions. They provide the most integrated solutions for multi-cell management. The main differences from smaller packs are the higher series voltages, daisy chain communication and noise immune signaling.
Techniques
In either case, voltage monitoring, temperature monitoring and active balancing tend to be the primary needs of a BMS. Other features such as redistribution tend to be less critical and often do not warrant the added cost and hardware.
Solutions
Unfortunately, even though nearly all BMS designs have the same goals, rarely is there an all in one solution. Solutions are based on number of cells, voltages (chemistry), tolerance for loss, communication method etc. These variables are not all standardized between one project and another. Furthermore, technologies keep changing. Linear is considering replacing CAN-BUS with shielded Ethernet. ADC accuracy is increasing. Sample rates are increasing.
The tried and true method is just simple active balancing. That is extra voltage on a cell is bled off resistively. Other than that, the rest of the system is a simple matter of reading all the cell voltages efficiently.
The Future
Eventually, we will see a more robust landscape with better standardization. Companies like Elithion or Nuvation are designing BMS solutions that are nearly drop in solutions. Chip designers are getting a better understanding of customers needs and have already sought to distinguish between the different types of li-ion needs based on different industries. This will mean that we’ll start only paying for features we need. Even battery cell manufacturers are standardizing cell types. For now though, any battery design remains quite customized.
Among mainstream battery technologies, LiPo has the best energy density, so you will probably want to go this way. In your case, since you will use a regulator anyway, every configuration possible (including single cell combined with a step-up boost regulator). Once you have chosen the total energy capacity you need for your application and the cell configuration, there are two parameters to consider:
- Quality: for the best specific energy, you will need to get high quality cells, which are going to cost more.
- Discharge rating: cells are usually rated for a given maximum discharge current, usually expressed relatively to its capacity (for example, a 10C rating for a 1000mAh cell means that the max current is 10*1000mA = 10A). While higher C rating may mean a lower ESR, there is a trade-off and increasing C rating significantly lowers the specific energy. As an example, a 40C 2000mAh cell from a high quality chinese manufacturer I was looking at recently had a specific energy of about 140 Wh/kg while the 15C version had a specific energy of 170 Wh/kg. This difference can largely offset any loss due to slightly increased ESR.
Whatever configuration you will end up using, your require that the battery lasts at least 5h. Assuming little loss in DC-DC regulation, this means that the average current would be at most 0.2C and the peak current (from your numbers) about 0.6-1C. I would thus look for 5C-rated good-quality cells, which should get you 180Wh/kg or more.
Best Answer
Edited 2017 - changed recommended long life storage voltage and added comments on fast charging using some recent systems. RM.
What YOU do as regards several of these questions depends largely on what YOU are trying to achieve or test.
Discharge to cutoff is fully discharged (to whatever remaining % that voltage represents). That's the easy one :-)
Percent dropoff of current in tail sets final % of max possible charged reached. There was a superb table given here within last week or so. Can supply later if you don't find it.
Real Men™ plateau at 4.2V and tail down to 10% or even 5% of the constant current rate. This gets the battery full and knocks the stuffing out of it.
Others terminate the current tail at say 25% of cc value.
Optimum lifetime for ongoing usage is at about the end of the constant current phase. That makes it very easy to locate - charge at specified current until desired max voltage is reached, then charge at constant voltage as desired. Here "desired" is to stop immediately. This is the point at which batteries tend to give significantly longer whole of life mAh of storage without grossly reducing mAh capacity per cycle. This is liable to be the point where older "fast chargers" tell you they have finished. Actual % total claimed varies but probably 70% - 80% range.
Newer USB input fast chargers use the term differently. In the case of USB the maximum available charge current at 5V is 5A so that the battery MAY be able to be charged at ~= 6A for the CC part of the cycle using an efficient buck converter to drop voltage and raise current.
[For a buck converter: Vout x Iout = Vin x Iin x efficiency_of_conversion]
Some systems such as QuaqlComms Quick Charge system allow the use of higher charger voltages (9, 12, 20) with specifically designed equipment, so battery charging can be faster for a given voltage provided that the battery specification allows this.
Maximum charge rates for LiIon and LiPo batteries are usually C/1 = 1A per Ah of battery capacity.
At 5V, 5A a USB charger can charge a 6000 mAh 1 cell LiPO battery at max rate - so eg a 10,000 mAh single cell battery used in some larger tablets can not be charged at the allowed 10A ! rate.
For long life storage where actual stored capacity is unimportant, LiIon and LiPo cells should be stored at about 3.7V.
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Using cells without protection adds to the rich tapestry of life. As long as you don't mind the occasional scorch mark on the tapestry that's fine. Note that part of the protection is a one time high capacity fuse under the cap for when things get out of control. Undervoltage discharge destroys. Charging from below a certain voltage at full rate can get fun, I'm told. Charging at reduced rate can bring cell up, I'm told. Below another second level they say don't even think about it. I've had very poor success in trying to get LiIon to misbehave. I have a box of unprotected cells that are very uncooperative about venting with lame etc. Strange. Sony and Apple and even HP seem to be much better at it :-).