Fault Diagnosis Method for Lithium-Ion Battery Packs in Real-World Electric Vehicles Based on K-Means and the Fréchet Algorithm

[Image: see text] Battery failure has traditionally been a major concern for electric vehicle (EV) safety, and early fault diagnosis will reduce many EV safety accidents. However, the short-circuit signal is generally very weak, so it is still a challenge to achieve a timely warning of battery failure. In this paper, an initial microfault diagnosis method is proposed for the data of electric vehicles in actual operation. First, a robust locally weighted regression data smoothing method is proposed that can effectively remove noisy data and retain fault characteristics. Second, an ordinary-least-squares-based voltage potential feature extraction method is proposed, which can effectively capture the small fault features of battery cells and achieve early warning. Third, a reference cell selection method based on K-means clustering is proposed, which can effectively reduce the false alarms caused by the inconsistency of each cell. Fourth, the Fréchet algorithm is introduced into the field of battery pack fault diagnosis and combined with thresholds for battery pack fault diagnosis and localization to accomplish the diagnosis and early warning of minor faults. Finally, the fault diagnosis method is validated by three actual running electric vehicles to verify the effectiveness, reliability, and robustness of the method.