2001-01-0959 A Review of Cell Equalization Methods for Lithium Ion and Lithium Polymer Battery Systems

Lithium-based battery technology offers performance advantages over traditional battery technologies at the cost of increased monitoring and controls overhead. Multiple-cell Lead-Acid battery packs can be equalized by a controlled overcharge, eliminating the need to periodically adjust individual cells to match the rest of the pack. Lithium-based based batteries cannot be equalized by an overcharge, so alternative methods are required. This paper discusses several cell-balancing methodologies. Active cell balancing methods remove charge from one or more high cells and deliver the charge to one or more low cells. Dissipative techniques find the high cells in the pack, and remove excess energy through a resistive element until their charges match the low cells. This paper presents the theory of charge balancing techniques and the advantages and disadvantages of the presented methods. INTRODUCTION Lithium Ion and Lithium Polymer battery chemistries cannot be overcharged without damaging active materials [1-5]. The electrolyte breakdown voltage is precariously close to the fully charged terminal voltage, typically in the range of 4.1 to 4.3 volts/cell. Therefore, careful monitoring and controls must be implemented to avoid any single cell from experiencing an overvoltage due to excessive charging. Single lithium-based cells require monitoring so that cell voltage does not exceed predefined limits of the chemistry. Series connected lithium cells pose a more complex problem: each cell in the string must be monitored and controlled. Even though the pack voltage may appear to be within acceptable limits, one cell of the series string may be experiencing damaging voltage due to cell-to-cell imbalances. Traditionally, cell-to-cell imbalances in lead-acid batteries have been solved by controlled overcharging [6,7]. Leadacid batteries can be brought into overcharge conditions without permanent cell damage, as the excess energy is released by gassing. This gassing mechanism is the natural method for balancing a series string of lead acid battery cells. Other chemistries, such as NiMH, exhibit similar natural cell-to-cell balancing mechanisms [8]. Because a Lithium battery cannot be overcharged, there is no natural mechanism for cell equalization. Therefore, an alternative method must be employed. This paper discusses three categories of cell balancing methodologies: charging methods, active methods, and passive methods. Cell balancing is necessary for highly transient lithium battery applications, especially those applications where charging occurs frequently, such as regenerative braking in electric vehicle (EV) or hybrid electric vehicle (HEV) applications. Regenerative braking can cause problems for Lithium Ion batteries because the instantaneous regenerative braking current inrush can cause battery voltage to increase suddenly, possibly over the electrolyte breakdown threshold voltage. Deviations in cell behaviors generally occur because of two phenomenon: changes in internal impedance or cell capacity reduction due to aging. In either case, if one cell in a battery pack experiences deviant cell behavior, that cell becomes a likely candidate to overvoltage during high power charging events. Cells with reduced capacity or high internal impedance tend to have large voltage swings when charging and discharging. For HEV applications, it is necessary to cell balance lithium chemistry because of this overvoltage potential. For EV applications, cell balancing is desirable to obtain maximum usable capacity from the battery pack. During charging, an out-of-balance cell may prematurely approach the end-of-charge voltage (typically 4.1 to 4.3 volts/cell) and trigger the charger to turn off. Cell balancing is useful to control the higher voltage cells until the rest of the cells can catch up. In this way, the charger is not turned off until the cells simultaneously reach the end-of-charge voltage. END-OF-CHARGE CELL BALANCING METHODS Typically, cell-balancing methods employed during and at end-of-charging are useful only for electric vehicle purposes. This is because electric vehicle batteries are generally fully charged between each use cycle. Hybrid electric vehicle batteries may or may not be maintained fully charged, resulting in unpredictable end-of-charge conditions to enact the balancing mechanism. Hybrid vehicle batteries also require both high power charge (regenerative braking) and discharge (launch assist or boost) capabilities. For this reason, their batteries are usually maintained at a SOC that can discharge the required power but still have enough headroom to accept the necessary regenerative power. To fully charge the HEV battery for cell balancing would diminish charge acceptance capability (regenerative braking). CHARGE SHUNTING The charge-shunting cell balancing method selectively shunts the charging current around each cell as they become fully charged (Figure 1). This method is most efficiently employed on systems with known charge rates. The shunt resistor R is sized to shunt exactly the charging current I when the fully charged cell voltage V is reached. If the charging current decreases, resistor R will discharge the shunted cell. To avoid extremely large power dissipations due to R, this method is best used with stepped-current chargers with a small end-of-charge current.