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Yeah, I know what you mean about the wires. My original bms and the one that is currently fitted to my car uses an 8-cell board with an Atmel micro. It has a couple of LM324s to level shift and condition the cell voltages which are read by the 8-channel ADC. Each board has opto-coupled comms on a multidrop bus. It works OK but its a nightmare with a wire from each cell running off to a number of Molex connectors. It scares me just looking at it! Also, the regulations here now require you to have a fuse in each sense wire and that is just too difficult. The cell module bolted directly to the terminals doesn't require a fuse, although I have provided one by way of a bit of skinny track.
I'll send you a copy of the document describing how it works.
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Sometimes I sits and thinks and sometimes I just sits.
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