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Non-uniformity of Lithium-ion cells in a battery pack is inevitable and has become the bottleneck to the pack capacity, especially in the fast charging process. Therefore, a balancing approach is essentially required. This paper proposes an active online cell balancing approach in a tfast charging process using the state of charge (SOC) as balancing criterion. The goal of this approach is to complete pack balancing within the limited charging time. An adaptive extended Kalman filter (AEKF) is applied to estimate the pack cell SOC during the charging process to obtain accurate results under modeling errors and measurement noises. To implement the proposed AEKF, only one additional current sensor is required to obtain the current of each cell required for the SOC estimation. An experimental platform is established to verify the effectiveness of the proposed approach. The results show that the proposed balancing approach with the SOC as a balancing criterion can overcome the challenges of non-uniformity and flat voltage plateau and charge more capacity into a LiFePO 4 battery pack than those with the terminal voltage as a balancing criterion in the fast charging process.Keywords: lithium-ion battery pack; the active cell balancing for battery packs; fast charging with balancing; electric vehicles; adaptive extended Kalman filter; pack SOC estimation Highlights:• Adaptive extended Kalman filter (AEKF) is employed to estimate the pack cell state of charge (SOC) in real time, which is used as a balancing criterion to equalize cells in a LiFePO 4 battery pack in the fast charging process.• Only one additional current sensor in the chosen balancing circuit is required to accurately estimate pack cell SOC, leading to low cost implementation.• Balancing in the fast charging process based on online estimated SOC overcomes non-uniformity and allows more pack capacity to be charged. •Experimental platform is established to demonstrate that the performances based on the SOC criterion is better than those based on the terminal voltage criterion in terms of extra charged capacity of 2.07 Ah, equivalent to 13% of the nominal capacity of the chosen battery pack.

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Based on a low cost multi-switched inductor balancing circuit (MSIBC), a fuzzy logic (FL) controller is proposed to improve the balancing performances of lithium-ion battery packs instead of an existing proportional-integral (PI) controller. In the proposed FL controller, a cell's open circuit voltages (OCVs) and their differences in the pack are used as the inputs, and the output of the FL controller is the balancing current. The FL controller for the MSIBC has the advantage of maintaining high balancing currents over the existing PI controller in almost the entire balancing process for different lithium battery types. As a result, the proposed FL controller takes a much shorter time to achieve battery pack balancing, and thus more pack capacity can be recovered. This will help to improve the pack performance in electric vehicles and extend the serving time of the battery pack.

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