Rapid Prediction of Maximum Remaining Capacity in Lithium-Ion Batteries Based on Charging Segment Features and GA_DBO_BPNN

Rapid and accurate prediction of the maximum remaining life of lithium-ion batteries is a critical technical challenge for enhancing battery management system reliability and enabling the efficient secondary utilization of retired batteries. Traditional approaches that rely on full charge–discharge cycles or complex electrochemical models often suffer from long detection time and limited adaptability, making them unsuitable for fast testing scenarios. To address these limitations, this study proposes a novel capacity prediction method that integrates charging segment feature extraction with a back-propagation neural network (BPNN) co-optimized using the genetic algorithm (GA) and dung beetle optimizer (DBO). Leveraging the public CALCE datasets, key degradation-related features were extracted from partial charging segments to serve as inputs to the prediction framework. The hybrid GA_DBO algorithm is employed to jointly optimize the BPNN’s weights, learning rate, and activation thresholds. A comparative analysis is conducted across various charging durations (900 s, 1800 s, and 2700 s) to evaluate performance under different input lengths. Results reveal that the model using 1800 s charging segment features achieves the best overall accuracy, with a test set mean squared error (MSE) of 0.0001 Ah2, mean absolute error (MAE) of 0.0092 Ah, root mean square error (RMSE) of 0.0122 Ah, and a coefficient of determination (R2) of 99.66%, demonstrating strong robustness and predictive capability. This research overcomes the traditional reliance on full cycles, demonstrating the effectiveness of short charging segments combined with intelligent optimization algorithms. The proposed method offers a high-precision, low-cost solution for online battery health monitoring and rapid sorting of retired batteries, highlighting its significant engineering application potential.