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System-level assessment of dynamic reconfiguration for lifetime and cost outcomes in electric vehicle battery packs.

Created on 09 Jul 2026

Authors

Albert Škegro, Torsten Wik, Bo Bijlenga, Alexander Bessman, Changfu Zou

Published in

Nature communications. Volume 17. Issue 1. Jul 08, 2026. Epub Jul 08, 2026.

Abstract

The electrification of transport relies heavily on lithium-ion batteries, yet conventional fixed-configuration battery packs suffer from structural inefficiencies such as cell-to-cell variability and premature failure. Dynamic battery reconfiguration, enabled by intelligent control of switching hardware around individual cells, provides an alternative pack architecture. Here we present a systematic, battery technology-agnostic evaluation of the lifetime and economic benefits of reconfigurable battery packs using a statistically grounded framework based on detailed cell modelling across diverse design and usage conditions. We show that reconfigurable battery packs can extend battery lifetime by over 20%, particularly in high-voltage applications such as electric trucks and long-range passenger vehicles. Despite higher upfront costs, reconfigurable packs can reduce lifetime cost by deferring replacements and retaining greater residual value. A sensitivity analysis identifies robust thresholds for economic viability: battery capacities above approximately 50 kWh, annual driving distances below 12,150 km, and additional upfront costs under 7.16%. These findings position dynamic reconfiguration as a scalable, cost-optimised architecture for next-generation battery platforms, and provide a quantitative foundation for future hardware design, management software, and life-cycle sustainability assessments.

PMID:
42420304
Bibliographic data and abstract were imported from PubMed on 09 Jul 2026.

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