This paper proposes a framework for accurately estimating the state-of-charge (SOC) and current sensor bias, with the aim of integrating it into urban air mobility (UAM) with hybrid propulsion. Considering the heightened safety concerns in an airborne environment, more reliable state estimation is required, particularly for the UAM that uses a battery as its primary power source. To ensure the suitability of the framework for the UAM, a two-pronged approach is taken. First, realistic test profiles, reflecting actual operational scenarios for the UAM, are used to model the battery and validate its state estimator. These profiles incorporate variations in battery power flow, namely, charge-depleting and charge-sustaining modes, during the different phases of the UAM’s flight, including take-off, cruise, and landing. Moreover, the current sensor bias is estimated and corrected concurrently with the SOC. An extended Kalman filter-based bias estimator is developed and experimentally validated using actual current measurements from a Hall sensor, which is prone to noise. With this correction, a SOC estimation error is consistently maintained at 2% or lower, even during transitions between operational modes.

Since battery systems typically account for over 40% of the cost of an electric vehicle, their mid-life replacements are exceptional. Therefore, the battery’s lifespan must exceed that of the vehicle. To ensure long-term and safe use, accurate state-of-charge (SOC) estimation must be maintained throughout the battery’s lifespan. This requires appropriate updates to parameters, such as capacity, in the battery model. In this context, dual extended Kalman filters, which simultaneously estimate both states and parameters, have gained interest. While existing reports on simultaneous estimators seemed promising, our study found that they performed well under low levels of battery aging but encountered issues at higher levels. Accurately reflecting the actual physicochemical changes of the parameters in aging cells is challenging for two reasons: the limited number of measurements of terminal voltage available for numerous parameters, and the weak observability of the capacity. Therefore, we combined the simultaneous estimator with a capacity estimator operated separately during charging and a sequential estimator specialized for an enhanced self-correcting model, achieving SOC accuracy within 5% even when the SOH decreased by 30%. However, there is still much work to be carried out to implement sequential estimators in battery management systems operating in real time with limited computational resources.