Reconfigurable battery systems: Challenges and safety solutions using intelligent system framework based on digital twins

Research on Reconfigurable Battery Systems (RBS) is gaining emphasis over the traditional fixed topology of the battery pack due to its advantages of adapting flexible topology (series-parallel) during its operation in the pack for meeting the non-linear time-dependent load requirements. There could emerge serious issues such as those related to safety due to malfunction of the switching circuit, heat generation from switches during frequent switching of circuits, charging temperature rise, increased charging time, sensing issues arising from the use of low-accuracy voltage/current sensors, state of charge/state of health estimation, and cost issues due to the use of increasing number of switches, fuses, contactors, relays, circuit breakers etc. To address these mentioned issues, the problem of optimal switching circuit topology for RBS is formulated as a mathematical multi-objective optimisation problem. An intelligent system framework based on digital twins is proposed. The proposed framework is further extended to a life cycle management approach that includes the interactions among pack design, pack assembly and operational and recycling levels. This could provide greater access of real-time big data cloud storage to the battery designers, manufacturers and recycling industries, who can make use of it to optimise their designs, systems and operations.