Li-Ion batteries are deployed at exponential rate especially in transportation electrification sector where more than 1 TWh demand is expected by 2030. As the important thresholds of energy density cost and performance have been recently achieved. Due to the reduced and unpredictable life-time and large effort needed for manufacturing, second-lifetime usage or recycling, the total CO2 footprint is still a big challenge.

Smart Battery is a new breakthrough in future BMS technology, where by featuring each cell in large packs with a bypass and AI, it becomes possible to achieve significant improved balancing of both temperature and state of charge leading to larger lifetime. Also, permanent bypass of faulted cells, will allow fault -tolerant operation, which is important for critical applications like air-transportation.

AI is used to provide health management and safety management including early detection of accelerated aging and thermal runaway warning.

Smart Battery BMS is designed as a retrofit that can be applied to conventional packs to improve lifetime performance and reduce CO2 footprint. It will transform the battery cells in building-blocks, that will significantly ease the design effort due to the capability of load management at cell level and software reconfiguration.

Smart Battery technology is designed to tackle the challenges posed by battery degradation and aging, factors which can considerably diminish the performance and lifespan of lithium-ion batteries. Leveraging advanced algorithms and control systems, Smart Battery optimizes the performance of the battery, mitigating power and capacity fade, and facilitates second-life applications. The key objectives of Smart Battery technology are:

1. Improved Battery Performance:

One of the primary objectives is to improve the overall performance of batteries. This is accomplished through the use of advanced algorithms and control systems that can optimize charging and discharging processes, balance cells, and monitor health status in real-time.

2. Extended Battery Lifetime:

Smart Battery technology aims to prolong the useful life of batteries, which can lead to significant cost savings for users and a reduction in electronic waste.

3. Enhanced Safety:

Safety is a significant concern with batteries, especially in relation to overcharging, overheating, and short-circuiting. Smart Battery technology employs continuous monitoring and control systems to prevent these issues and enhance overall battery safety.

4. Enable Second-Life Applications:

As batteries degrade, they can become unsuitable for their original purpose but still possess considerable capacity. Smart Battery technology can facilitate the repurposing of these batteries for secondary uses, contributing to a circular economy.

5. Fast Charging Capabilities:

Reducing the time it takes to charge a battery can significantly improve the user experience, particularly in the context of electric vehicles. But the battery performance degradation is a major limiting factor in fast charging. Therefore, by mitigating this degradation with the application of pulse current, Smart Battery technology can effectively support and improve fast charging processes.

The methodology and strategy of the Smart Battery technology involve the integration of power electronics, artificial intelligence, and advanced control systems to optimize battery performance and extend its lifetime. The Smart Battery utilizes power electronics for the bypass device, which allows for the operation of cells with unequal characteristics without performance limitations. This ensures that all cells in the battery pack can contribute effectively without being hindered by weaker cells.

In terms of charging strategies, the Smart Battery employs pulsed current charging/discharging techniques. Experimental results have shown that pulse current can extend battery lifetime by up to 80% compared to constant current charging. Pulsed current charging helps slow down degradation modes associated with high C-rate operation over long periods, such as the loss of active material.

Additionally, the Smart Battery incorporates artificial intelligence for performance optimization. It utilizes a lifetime prediction framework that accurately estimates the short-term state of health (SOH) long-term lifetime predictions, and knee point prediction. This long-term perspective and knee identifying aid in scheduling necessary maintenance or replacement to ensure continued, uninterrupted performance, and cost reduction.

The concept of a ‘battery digital twin’ is also incorporated within the Smart Battery framework, creating a virtual model mirroring the physical battery. This digital representation permits real-time monitoring, speed-up simulation, and analysis, providing valuable insights for performance optimization and predictive maintenance.

Thermal management is critical for ensuring the safety and performance of lithium-ion batteries. As another critical component of the Smart Battery, thermal management involves impedance-based temperature estimation, the battery’s temperature regulation with bypass current, thus to optimize battery performance, prevent overheating and thermal runaway.