Design and Experimental Evaluation of a Fast LiFePO4 Battery Charger Using Fuzzy Logic Control: A Statistical and Simulation-Based Study
DOI:
https://doi.org/10.61952/jlabw.v2i4.628Keywords:
LiFePO4 battery, fast charging, fuzzy logic control, DC-DC buck converter, thermal management, statistical analysisAbstract
Fast charging of lithium iron phosphate (LiFePO4) batteries is an important requirement for electric vehicles and renewable-energy storage systems. However, the conventional constant-current–constant-voltage (CC-CV) charging method offers limited flexibility for reducing charging time when voltage and thermal constraints are approached. This study presents the design and evaluation of a Mamdani fuzzy logic controller (FLC) for regulating the PWM duty cycle of a DC-DC buck converter according to the voltage and temperature errors of a three-cell LiFePO4 battery pack rated at 9.6 V and 1.1 Ah. A first-order Thevenin battery model coupled with a lumped thermal model was developed and implemented in MATLAB/Simulink. The FLC and conventional CC-CV methods were evaluated at charging rates of 1C, 2C, and 2.5C. For the statistical analysis, each configuration was simulated ten times using randomized perturbations in internal resistance and ambient temperature, providing a Monte Carlo sensitivity study with (n=10) independent runs per group. Experimental bench tests were used to validate the simulation model and to confirm the representative charging behavior of the proposed controller. The model reproduced the measured terminal voltage with an RMSE of 0.12 V and a MAPE of 1.8%. Welch’s two-sample t-tests showed that the FLC reduced charging time by approximately 8.5–8.7% compared with CC-CV at all three charging rates ((p<0.001)), with Cohen’s (d) values ranging from 2.9 to 5.0. At 2.5C, the electrical conversion efficiency was statistically comparable between the two methods, reaching 83.28% for the FLC and 83.12% for CC-CV ((p=0.17)). In addition, the FLC reduced the simulated peak pack temperature from 36.0°C to 34.4°C at 2.5C. A Lyapunov-type analysis further supports the boundedness and practical stability of the closed-loop system. The results demonstrate that fuzzy duty-cycle control can significantly reduce fast-charging time and thermal stress while maintaining conversion efficiency comparable to that of conventional CC-CV charging. The overall efficiency remains primarily limited by converter losses rather than by the control strategy.
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