Optimized multi-stage constant current fast charging protocol suppressing lithium plating for lithium-ion batteries using reduced order electrochemical-thermal-life model

Multi-stage Constant Current (MCC) is a state-of-the-art fast-charging protocol considering battery aging. It divides the charging process into multiple stages, each with a different current amplitude based on specific transition criteria, significantly influencing battery performance, such as charging time, degradation rate, and thermal effects. A key challenge in designing MCC protocols is addressing the lithium plating (LiP), which can accelerate degradation and pose a severe risk of thermal runaway. Since the LiP onset conditions vary between fresh and aged cells, this paper proposes an optimized MCC (O-MCC) charging protocol suppressing LiP based on the battery's state of health. To accurately simulate LiP conditions, different platforms of reduced-order electrochemical-thermal-life models are designed, compared, and optimized for speed and accuracy using a genetic algorithm, resulting in a 36.4 % reduction in computational time while maintaining the accuracy of the Pseudo Two-Dimensional model. The Nonlinear Model Predictive Control algorithm is then used to optimize the MCC protocol, minimizing charging time while preventing LiP throughout life. Experimental results show that O-MCC reduces charging time by 11.7 % and capacity loss by 59.4 %, enhancing battery safety. Additionally, O-MCCs with varying constraints are developed to meet specific demands and simulated at the battery pack level.