Optimal Fast-Charging Strategy for Cylindrical Li-Ion Cells at Different Temperatures

Ensuring efficiency and safety is critical when developing charging strategies for lithium-ion batteries. This paper introduces a novel method to optimize fast charging for cylindrical Li-ion NMC 3Ah cells, enhancing both their charging efficiency and thermal safety. Using Model Predictive Control (MPC), this study presents a cost function that estimates the thermal safety boundary of Li-ion batteries, emphasizing the relationship between the temperature gradient and the state of charge (SoC) at different temperatures. The charging control framework combines an equivalent circuit model (ECM) with minimal electro-thermal equations to estimate battery state and temperature. Optimization results indicate that at ambient temperatures, the optimal charging allows the cell’s temperature to self-regulate within a safe operating range, requiring only one additional minute to reach 80% SoC compared to a typical fast-charging protocol (high current profile). Validation through numerical simulations and real experimental data from an NMC 3Ah cylindrical cell demonstrates that the simple approach adheres to the battery’s electrical and thermal limitations during the charging process.