I've heard some of our big battery guys on the forum talk about how 100% SOC stresses the battery so that makes sense but what about cell balancing? Can the BMS balance the cells to a uniform 80% SOC, or just cut off when some or most or one of the cells hits 80% ?
Just an FYI.. your zero does not fill the battery to 4.20v for each cell.. it stops at 4.15v for that reason, and tells the end user its 100% All EVs do this. The leaf caught a bad wrap because they had some early issues.. mostly didnt put any cell cooling into the design, used a thermally sensitive chemistry, and so this 80% is a band-aid fix for that so some users can feel better about it.
As far as the Leaf BMS goes, it is always balancing. each module is 2S2P and each 2P "cell" is constantly monitored and balanced via a tiny 1206 size 430 ohm resistor... its only 10mA of current so it takes FOREVER to balance, but since they are never far off, its not a problem. They're stable and reliable cells, just heat sensitive. While I like their module layout, its horribly space inefficient and lacks cooling. Something like what Chevy does is much nicer.. long stacks of cooling plate->cell->cooling plate->cell... with the plates thermally connected to liquid coolant.
Im actually playing with a leaf BMS right now based off the info gleaned from here:
http://www.wolftronix.com/E10_LithiumUpgrade/index.html I have a leaf module pack I am putting on a gokart for fun.. so I figured I would mess with the leaf BMS too... mostly im using the circuit board and the BMS chips on it, since I cant really source them elsewhere and WolfTronix already showed us how to talk to the chips.