SOH- and Temperature-Aware Adaptive SOC Boundaries for Second-Life Li-Ion Batteries in Off-Grid PV–BESSs

In this study, an adaptive state-of-charge (SOC) boundary strategy (ASBS) is proposed that dynamically adjusts the admissible upper and lower SOC limits of second-life lithium-ion batteries in off-grid photovoltaic battery energy storage systems (PV-BESSs) based on real-time state of health (SOH) and temperature feedback. The strategy is formulated using a unified electrical–thermal–aging model with an online state estimator and ensures both electrical safety and power feasibility while remaining fully compatible with standard energy management functions. Two representative simulations—a single-day operating profile and a continuous thirty-day sequence—demonstrate the effectiveness of the ASBS. In the twenty-four-hour case, the duration spent in high state-of-charge conditions is reduced by approximately 0.30–0.50 h, the abrupt end-of-charging transition is eliminated, and the temperature rise is slightly moderated, all without any loss of energy supply. Over thirty days, the difference between the ASBS and a fixed state-of-charge window remains effectively zero for almost all hours, with only a brief midday deviation of −4 to −5 percentage points and no cumulative drift. Indicators of electrical and thermal stress improve substantially, including an approximate 70% reduction in the root mean square charging current. These results confirm that the ASBS provides a practical and non-intrusive means of mitigating stress on second-life lithium-ion batteries while preserving full energy autonomy in off-grid photovoltaic systems.