With the wide-scale deployment of battery packs in a variety of applications, some life cycle challenges are coming to light. These challenges include extending their operational life as a pack given their increasing cell-level imbalances and repurposing their cells into new battery packs to give them a second life, e.g., in grid storage. This paper presents a new circuit topology addressing both issues using active (controlled and nondissipative) cell-to-cell balancing for online operation, i.e., while the battery energy storage system is in use. The proposed circuit design is fast and safe for balancing, relying on current control to target each individual cell’s maximum charging and discharging current, while taking into account the pack current. The design has the lowest number of switches and circuit components compared to the state-of-the-art techniques, and is also flexible, allowing for the addition or replacement of cells in series. Its practical hierarchical control system enables speed, reliability, and reconfigurable limits in real-time operation on the individual cells. Experimental validation is carried out on homogeneous and heterogeneous packs in online operation, and the results demonstrate the speed and efficacy of the proposed technique.

2026

19

17

08/2026