A Data-Driven LiFePO4 Battery Capacity Estimation Method Based on Cloud Charging Data from Electric Vehicles

The accuracy of capacity estimation is of great importance to the safe, efficient, and reliable operation of battery systems. In recent years, data-driven methods have emerged as promising alternatives to capacity estimation due to higher estimation accuracy. Despite significant progress, data-driven methods are mainly developed by experimental data under well-controlled charge-discharge processes, which are seldom available for practical battery health monitoring under realistic conditions due to uncertainties in environmental and operational conditions. In this paper, a novel method to estimate the capacity of large-format LiFePO4 batteries based on real data from electric vehicles is proposed. A comprehensive dataset consisting of 85 vehicles that has been running for around one year under diverse nominal conditions derived from a cloud platform is generated. A classification and aggregation capacity prediction method is developed, combining a battery aging experiment with big data analysis on cloud data. Based on degradation mechanisms, IC curve features are extracted, and a linear regression model is established to realize high-precision estimation for slow-charging data with constant-current charging. The selected features are highly correlated with capacity (Pearson correlation coefficient < 0.85 for all vehicles), and the MSE of the capacity estimation results is less than 1 Ah. On the basis of protocol analysis and mechanism studies, a feature set including internal resistance, temperature, and statistical characteristics of the voltage curve is constructed, and a neural network (NN) model is established for multi-stage variable-current fast-charging data. Finally, the above two models are integrated to achieve capacity prediction under complex and changeable realistic working conditions, and the relative error of the capacity estimation method is less than 0.8%. An aging experiment using the battery, which is the same as those equipped in the vehicles in the dataset, is carried out to verify the methods. To the best of the authors' knowledge, our study is the first to verify a capacity estimation model derived from field data using an aging experiment of the same type of battery.