Adaptive Hybrid Switched-Capacitor Cell Balancing for 4-Cell Li-Ion Battery Pack with a Study of Pulse-Frequency Modulation Control

Battery cell balancing is crucial in series-connected lithium-ion packs to maximize usable capacity, ensure safe operation, and prolong cycle life. This paper presents a comprehensive study and a novel adaptive duty-cycled hybrid balancing system that combines passive bleed resistors and an active switched-capacitor (SC) balancer, specifically designed for a 4-cell series-connected battery pack. This work also explored open circuit voltage (OCV)-driven adaptive pulse-frequency modulation (PFM) active balancing to achieve higher efficiency and better balancing speed based on different system requirements. Finally, this paper compares passive, active (SC-based), and adaptive duty-cycled hybrid balancing strategies in detail, including theoretical modeling of energy transfer and efficiency for each method. Simulation showed that the adaptive hybrid balancer speeds state-of-charge (SoC) equalization by 16.24% compared to active-only balancing while maintaining an efficiency of 97.71% with minimal thermal stress. The simulation result also showed that adaptive active balancing was able to achieve a high efficiency of 99.86% and provided an additional design degree of freedom for different applications. The results indicate that the adaptive hybrid balancer offered an excellent trade-off between balancing speed, efficiency, and implementation simplicity for 4-cell Li-ion packs, making it highly suitable for applications such as high-voltage portable chargers.