Physics-Based Analysis of Cell Imbalances and Aging in Lithium-Ion Battery Modules and Packs

Ayalasomayajula, Surya Mitra; Preger, Yuliya; Mueller, Jacob Andreas; Allu, Srikanth

doi:10.1149/1945-7111/adf66f

Physics-Based Analysis of Cell Imbalances and Aging in Lithium-Ion Battery Modules and Packs

Journal Article · Wed Aug 20 00:00:00 EDT 2025 · Journal of the Electrochemical Society

DOI:https://doi.org/10.1149/1945-7111/adf66f· OSTI ID:2584508

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Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)
Sandia National Lab. (SNL-NM), Albuquerque, NM (United States)

Lithium-ion battery (LIB) packs are a key solution for grid-scale energy storage, enabling grid resilience and supporting critical infrastructure. LIB modules and packs experience current imbalances and uneven cell aging due to various design and operational factors, and require a battery management system (BMS) to continuously monitor and control. In this context, a physics-based modeling framework for LIB modules and packs (liionpack) was enhanced to identify design and control strategies that minimize current imbalance and improve module/pack operation. Simulations of an 8-cell parallel-connected module demonstrate that reducing current imbalance leads to more uniform cell aging and improved module/pack-level degradation predictions. The analysis shows that current imbalance are affected by the electrical resistances. Terminal location significantly affects imbalance, with opposite-end terminal connections at intermediate branches minimizing the imbalance, and the pack circuit construction influences the accuracy of physics-based analysis at the pack scale. This framework enables design optimization of modules and packs through a fast and easy evaluation of pack performance and aging, and supports the development of aging-informed balancing strategies compatible with BMS implementation. Thereby, offering practical pathways to improve reliability and cycle life predictions in large-scale battery energy storage systems.

View Accepted Manuscript (DOE)

Research Organization:: Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States); Sandia National Lab. (SNL-NM), Albuquerque, NM (United States)

Sponsoring Organization:: USDOE National Nuclear Security Administration (NNSA); USDOE Office of Electricity (OE)

Grant/Contract Number:: AC05-00OR22725; NA0003525

OSTI ID:: 2584508

Alternate ID(s):: OSTI ID: 3020958

Report Number(s):: SAND--2026-17976J; 1773295

Journal Information:: Journal of the Electrochemical Society, Journal Name: Journal of the Electrochemical Society Journal Issue: 8 Vol. 172; ISSN 1945-7111; ISSN 0013-4651

Publisher:: IOP PublishingCopyright Statement

Country of Publication:: United States

Language:: English

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