Enhanced Battery Pack Consistency: A Hierarchical Active Balancing System Combining Bidirectional Buck–Boost and Flyback Converters

Series-connected lithium-ion battery packs are widely used in electric vehicles (EVs). However, inevitable inconsistency among cells can cause charge imbalance, accelerated aging, and reduced system safety. To improve the consistency of series-connected battery packs under complex EV operating conditions, this study proposes a hierarchical active balancing system. Bidirectional Buck–Boost converters are employed for intra-group balancing, and distributed flyback converters are used for inter-group balancing. A multi-stage coordinated balancing control strategy is further developed to reduce control complexity and improve balancing efficiency. A 16-cell series-connected battery pack model is established in MATLAB R2024a/Simulink and evaluated under resting, charging, and discharging conditions. The results show that, compared with the conventional single-layer Buck–Boost balancing topology, the proposed method reduces the balancing time by 58.09%, 57.97%, and 58.06%, respectively. These results indicate that the proposed system can effectively improve the consistency and balancing performance of series-connected battery packs, providing a scalable solution for EV battery management systems.