Project Report on

Optimizing Battery Life Through Rigorous Testing

BACHELOR OF TECHNOLOGY IN ELECTRICAL AND

ELECTRONICS ENGINEERING

Submitted by
[Link](N200431)
[Link](N200719)
[Link](N200577)
[Link] (N201117)
[Link] (N200641)
[Link] (N200342)

Under the Esteemed Guidance of

Mr.T MUTHU KUMARAN
Table of Contents
1 Introduction 6
1.1 Abstract . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.2 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.3 Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.4 Literature Survey . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.4.1 Degradation mechanisms of lithium-ion battery cells: . . . . . . . 9
1.4.2 Critical review of state of health estimation methods of Li-ion bat-
teries for real applications: . . . . . . . . . . . . . . . . . . . . . . 10
1.4.3 Fuzzy-Super twisting control implementation of battery/super ca-
pacitor for electric vehicles: . . . . . . . . . . . . . . . . . . . . . 10
1.4.4 Vehicle Speed Optimized Fuzzy Energy Management for Hybrid
Energy Storage System in Electric Vehicles: ............ 10
1.4.5 Stochastic Control of Predictive Power Management for Battery or Supercapacitor
Hybrid Energy Storage Systems of Electric Vehicles: 11
1.5 Circuit Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.6 Simulation Results .............................. 12
1.7 References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Chapter 1

Introduction

1.1 Abstract
The project ”Optimizing Battery Life Through Rigorous Testing” focuses on
extending the operational lifespan and efficiency of rechargeable batteries through
comprehensive experimental evaluation. As battery-powered devices become
increasingly essential in sectors such as consumer electronics, electric vehicles, and
renewable energy storage, optimizing battery performance has emerged as a critical
engineering challenge. This project aims to identify the key factors influencing battery
degradation by subjecting various battery types to controlled and repeatable testing
conditions. Tests include accelerated aging through charge-discharge cycling,
temperature stress analysis, and performance under variable load conditions. Data
gathered from these tests is analyzed to uncover degradation patterns and efficiency loss
over time. The project also investigates the impact of different charging protocols, such
as fast charging versus trickle charging, on overall battery health. Using this empirical
data, optimized usage guidelines and charging strategies are developed to minimize wear
and prolong battery life. Additionally, predictive models are created to estimate
remaining useful life (RUL) based on real-time usage data. The results demonstrate that
careful management of operating conditions and charging behavior can significantly
enhance battery durability. This research provides valuable insights for manufacturers,
designers, and end-users aiming to improve battery reliability and reduce environmental
impact through longer service life.

1.2 Introduction
In the modern world, batteries are the lifeblood of countless devices and
technologies, from smartphones and laptops to electric vehicles (EVs) and large-scale
energy storage systems. As society shifts further toward mobility, renewable energy, and
sustainability, the demand for efficient, durable, and reliable battery systems continues
to grow at an unprecedented rate. However, despite advancements in battery chemistry
and design, battery degradation remains a persistent challenge, directly impacting device
performance, user satisfaction, operational costs, and environmental sustainability. To
address this issue, the project *”Optimizing Battery Life Through Rigorous Testing”* aims
to systematically investigate the factors contributing to battery wear and to develop
strategies for extending battery lifespan through controlled and data-driven testing
methodologies.
 Batteries, especially lithium-ion types, are complex electrochemical systems sensitive
to numerous external and internal factors. Temperature, charge-discharge cycles, current
loads, depth of discharge, state of charge, and charging protocols all influence battery
aging and performance degradation. Over time, these influences lead to capacity fade,
increased internal resistance, and, ultimately, end-of-life failure. For users and
manufacturers alike, these effects translate into higher costs, reduced reliability, and
increased electronic waste. In response, optimizing battery life has become a key research
area, not only to improve product quality and consumer experience but also to contribute
to environmental conservation and economic efficiency.
Rigorous battery testing plays a vital role in understanding how and why batteries
degrade under different conditions. By recreating real-world usage patterns in a
controlled laboratory environment, researchers can isolate specific variables, monitor
battery behavior over time, and identify stressors that accelerate degradation. Unlike
passive observation, this proactive approach allows for precise experimentation, early
detection of faults, and the development of mitigation strategies. The insights gained from
such testing are instrumental in designing smarter battery management systems (BMS),
improving energy efficiency, and extending usable life cycles. Furthermore, rigorous
testing enables manufacturers to refine battery designs, enhance safety protocols, and
ensure quality control.
The goal of this project is to go beyond surface-level evaluations and engage in a
thorough, multi-dimensional testing process that reveals deep insights into battery aging
mechanisms. By implementing a series of repeatable and scalable tests—ranging from
simple charge-discharge cycling to complex thermal and load simulations—this research
aims to create a robust database of performance metrics. These metrics will then be
analyzed to draw correlations between usage behavior and long-term performance
outcomes. The ultimate objective is to generate optimized usage guidelines, predictive
models, and adaptive charging protocols that can significantly extend battery life without
sacrificing performance or user convenience.
In conclusion, the project *”Optimizing Battery Life Through Rigorous Testing”*
represents a critical step toward more efficient, reliable, and sustainable energy storage
systems. Through a structured, data-intensive testing regimen, this research seeks to
uncover the complex dynamics of battery degradation and provide actionable solutions
for extending operational life. As our dependence on battery-powered technologies
continues to grow, such efforts are essential for supporting innovation, promoting
sustainability, and delivering value across consumer, industrial, and environmental
domains. A battery that degrades quickly leads to shorter driving distances and increased
need for replacement—issues that deter widespread EV adoption. Similarly, in renewable
energy systems that depend on battery storage, such as solar power installations, battery
degradation can severely limit energy availability and reduce return on investment. Thus,
improving battery longevity through rigorous testing is not only a technical necessity but
also a strategic imperative in the global transition toward clean and sustainable energy
systems.
1.3 Objectives
1. Identify Key Degradation Factors Determine the main physical, chemical,
andenvironmental variables that contribute to battery wear and performance decline.
2. Develop a Standardized Testing Framework Create a consistent and
repeatabletesting methodology to evaluate battery performance under controlled and
accelerated conditions.
3. Simulate Real-World Usage Scenarios Design testing environments that
mimicreal-life usage patterns, including variable loads, charge/discharge cycles, and
temperature fluctuations.
[Link] the Impact of Charging Protocols Compare different charging strategies (e.g.,
fast charging, slow charging, trickle charging) and their effects on battery longevity and
efficiency.
5. Measure and Monitor Battery Parameters Collect real-time data on key
batterymetrics such as voltage, current, temperature, internal resistance, and capacity
fade over time.
6. Apply Data Analytics and Machine Learning Use statistical analysis and
machinelearning models to identify degradation trends, predict failure points, and
optimize battery usage patterns.
7. Develop Adaptive Charging Algorithms Create intelligent charging methods
thatadjust dynamically based on battery condition, usage behavior, and environmental
factors.
8. Conduct Post-Mortem Battery Analysis Examine aged and degraded battery cells
tounderstand structural and chemical changes contributing to performance loss.
9. Formulate Best Practices for End-Users Generate actionable recommendations
forconsumers and industries to extend battery life through proper usage and
[Link] to Sustainable Battery Usage Support environmental goals by
reducing battery waste and promoting energy efficiency through longer battery
lifespans.

1.4 Literature Survey

1.4.1 Degradation mechanisms of lithium-ion battery cells:
This review provides a detailed exploration of the chemical and physical
degradation processes in lithium-ion batteries, including SEI layer growth, lithium
plating, and thermal instability. The authors discuss how operational variables such as
charge rates, temperature, and depth of discharge significantly influence the rate of
degradation. This foundational knowledge helps define what stress factors should be
replicated in controlled tests and informs the selection of critical parameters to monitor.
For this project, the study offers a roadmap to simulate real-world battery aging
conditions and target the most impactful variables during rigorous [Link]
compared to the battery-only configuration, the HESS controlled by the rule-based
strategy can reduce 47 percent and 60percent of the ESS life cycle cost along the typical
China Bus Driving Cycle and the Urban Dynamometer Driving Schedule, respectively. This
paper also proves that a welltuned rule-based strategy, which can be easily implemented
in a vehicle, presents rather good performance when compared to the DP approach. In
addition, the proposed strategy performance can be further improved by increasing the
SC usage.

1.4.2 Critical review of state of health estimation methods of Li-ion

batteries for real applications:
Berecibar and colleagues analyze the strengths and limitations of various State of
Health (SoH) estimation techniques, ranging from empirical models to advanced machine
learning approaches. Their review stresses the difficulty of accurately assessing battery
health in dynamic conditions, which aligns with the project’s goal of developing robust,
real-time testing systems. Their insights guide the selection of appropriate diagnostic and
predictive tools for monitoring battery condition during and after testing cycles.

1.4.3 Fuzzy-Super twisting control implementation of battery/super

capacitor for electric vehicles:
Fuzzy logic energy management strategy (EMS), applied to a battery–super
capacitor hybrid energy system and associated with a permanent magnet synchronous
motor (PMSM) which emulates the traction part of an electric vehicle (EV). On the sources
side, the fuzzy logic supervisor acts in a smart way to permute smoothly between the
various operations modes via an efficient power frequency splitting. In addition, it
permits a quite regulation of both the DC bus and the super-capacitor (SC) voltages
regardless of the speed profile variations to ensure an optimal power flow to the load and
to keep the SC operation in a safe voltage range while providing or absorbing power in
transients. On the traction side, a second order sliding mode control called ‘super-
twisting’ (ST), associated with a space vector modulation (SVM) strategy is applied to
ensure both decoupled torque and flux control under low torque and flux ripples.

1.4.4 Vehicle Speed Optimized Fuzzy Energy Management for Hybrid

Energy Storage System in Electric Vehicles:
Energy management strategy (EMS) is a key issue for hybrid energy storage system
(HESS) in electric vehicles. By innovatively introducing the current speed information, the
vehicle speed optimized fuzzy energy management strategy (VSO-FEMS) for HESS is
proposed in this paper. Firstly, the pruned fuzzy rules are formulated by the SOC change
of battery and super-capacitor to preallocate the required power of vehicle. Then, the
real-time vehicle speed is used to optimize the pre-allocated results based on the
principle of vehicle dynamics, so as to realize the optimal allocation of required power.
To validate the proposed VSO-FEMS strategy for HESS, simulations were done and
compared with other EMSs under the typical urban cycle in China (CYC-CHINA). Results
show that the final SOC of battery and super-capacitor are optimized in varying degrees,
and the total energy consumption under the VSO-FEMS strategy is 2.43 percent less than
rule-based strategy and 1.28 percent less than fuzzy control strategy, which verifies the
effectiveness of the VSO-FEMS strategy.
1.4.5 Stochastic Control of Predictive Power Management for Battery
or Supercapacitor Hybrid Energy Storage Systems of Electric
Vehicles:
A neural network (NN) based methodology for power demand prediction and a
power distribution strategy for battery/supercapacitor hybrid energy storage systems of
pure electric vehicles. To develop an efficient prediction model, driving cycles are first
grouped and distinguished as three different driving patterns. For each driving pattern,
characteristic parameter data that could better featured driving cycles are extracted
effectively and used to train NN. The predictive information combined with its error is
subsequently used for power distribution. Then, to deal with different dynamics of
battery and supercapacitor systems, a frequency splitter is used and its frequency is
further optimized by a particle swarm optimization algorithm to minimize the total cost
including battery degradation and system energy for each driving pattern. Based on these
efforts, a real-time predictive power management control strategy is finally proposed. To
verify its effectiveness, simulation has been conducted to compare with the state-of-the-
art control strategy under a speed profile composing of five standard driving cycles.
Results show that obviously enhanced performance can be achieved by the proposed
control strategy.

1.5 Circuit Diagram

1.6 Simulation Results
for load 1

for load 2

Speed vs Torque Graph

1.7 References
1. Sellali, M.; Abdeddaim, S.; Betka, A.; Djerdir, A.; Drid, S.; Tiar, M. Fuzzy-Super
twisting control implementation of battery/supercapacitor for electric vehicles.
ISA Trans. 2019, 95, 243–253. [CrossRef] [PubMed]

2. Zhang, X.; Lu, Z.; Lu, M. Vehicle speed optimized fuzzy energy management for
hybrid energy storage system in electric [Link] 2020, 2020,
2073901.[CrossRef]

3. Zhang, Q.; Deng, W.; Li, G. Stochastic control of predictive power management for
battery/supercapacitor hybrid energy storage systems of electric vehicles. IEEE
Trans. Industr. Inform. 2017, 14, 3023–3030. [CrossRef]

4. Wu, Y.; Huang, Z.; Liao, H.; Chen, B.; Zhang, X.; Zhou, Y.; Liu, Y.; Li, H.; Peng, J.
Adaptive power allocation using artificial potential field with compensator for
hybrid energy storage systems in electric vehicles. Appl. Energy 2020, 257,
113983. [CrossRef]

5. Sun, L.; Feng, K.; Chapman, C.; Zhang, N. An Adaptive Power Split Strategy for
Battery-Supercapacitor Powertrain–Design,Simulation and Experiment. IEEE
Trans. Power Electron. 2017, 32, 9364–9375. [CrossRef]

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9. Pathak, A., Hu, Y. C., Zhang, M. (2012) – Fine-grained Power Modeling for
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10. Nath, S. (2010) – ACE: Exploiting Correlation for Energy-Efficient and Continuous
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