Browse Topic: Energy storage systems

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Signal Integrity in Distributed BMS: Reliable SPI and Ethernet Communication for Next-Gen EVs2026-01-0171To be published on 04/07/2026
Distributed battery management systems (BMS) are critical for scaling electric vehicle packs to hundreds of cells, but reliable high-speed communication between modules remains a challenge. Daisy-chained SPI and CAN FD are widely deployed today, while Ethernet is being evaluated for next-generation systems that require higher bandwidth, synchronization, and diagnostics. This paper examines the signal integrity (SI) challenges facing distributed BMS communication, including skew, jitter, crosstalk, and electromagnetic interference (EMI) across PCB traces and wiring harnesses. HyperLynx and SPICE-based simulations are combined with experimental results on a 192-cell test platform to quantify the impact of layout constraints, impedance mismatches, and harness parasitics. Results show that poor SI design can reduce signal margins by more than 18 dB, leading to data corruption and diagnostic failures. Co-design strategies for PCB routing, termination, and shielding are proposed, achieving
Abdul Karim, Abdul Salam
Investigation of CDI and TCI Ignition Charactertistics for Lean Hydrogen–Air Mixtures in a Constant Volume Combustion Chamber2026-01-0327To be published on 04/07/2026
The discharge characteristics of ignition systems strongly influence the formation of flame kernels under lean-burn conditions. In this study, two ignition strategies are compared. A capacitor discharge ignition (CDI) system characterized by discharge energy of 1–5 mJ with discharge current around 300 mA and short discharge duration (~50 μs). A transistor coil ignition (TCI) system delivering discharge energy of 30–50 mJ with lower discharge current (~100 mA) and millisecond-scale discharge duration. These two systems represent distinct discharge current profiles, namely “high-current/short-duration” and “low-current/long-duration.” The influence of discharge current profile on flame kernel formation and early flame development in lean hydrogen–air mixtures is investigated. Experiments are conducted in a constant-volume combustion chamber with hydrogen–air mixtures at various global equivalence ratios. Both quiescent and flow conditions are considered. High speed shadowgraph imaging is
Cong, Binghao, Jin, Long, Yu, Xiao, Zheng, Ming
Thermal Characterization of an Automotive High Voltage Junction Box2026-01-0390To be published on 04/07/2026
The high voltage battery junction box (HVJB) controls and protects the high voltage connections of the battery pack to the traction, auxiliary and charging systems. HVJBs are composed of busbars, contactors, fuses and other protection systems. The health of the HVJB is paramount to ensure performance and reliability of electric vehicles. However sensing and monitoring in the HVJB is often lacking due to cost, causing limited capability of the vehicle controller to estimate the status and health of the unit. This publication focuses on the experimentation of an automotive HVJB to characterize the operation and build the foundation for the development of prognostic algorithms for HVJB. A production HVJB has been acquired and heavily instrumented. Extensive testing are performed in adiabatic and in ambient conditions at various current levels for various durations of operation. The testing setup was calibrated and iterated based on preliminary results, and the testing conditions were
Arigo, Sam, Borgerson, Joe, D'Arpino, Matilde, ZHU, Di, Zhang, Liwen
Optimization of a Feedforward Neural Network Machine Learning Battery Model for an Automotive Pouch Cell2026-01-0386To be published on 04/07/2026
Modern battery management systems have a critical need for highly accurate battery terminal voltage models, which are a key component of algorithms which estimate or predict power capability, range, temperature, and other factors. While electro-chemical and equivalent circuit models are widely used for this purpose, they typically struggle to capture the complex, non-linear dynamics and degradation effects inherent in real-world battery operation, necessitating frequent recalibration. This study addresses these limitations by proposing a robust, data-driven approach for terminal voltage estimation using a feedforward neural network (FNN) machine learning model. An LG E66 cell, a high-performance lithium-ion battery with a Nickel Cobalt Manganese (NCM) cathode, was selected for this study due to its prevalent use in light duty electric vehicles. Data collected at temperatures ranging from 40 °C to -20 °C is used to train and test the models, with model error reported for HWFET, UDDS
Dehury, Biswanath, Nahidmobarakeh, Lucas, Panchal, Satyam, Gross, Oliver, Kollmeyer, Phillip
Thermal Management of Battery Modules under Fast Charging2026-01-0399To be published on 04/07/2026
Battery modules operate under diverse and complex conditions, such as driving cycles and fast charging. In these scenarios, effective thermal management is critical to ensuring safety and extending the battery's lifespan. Fast-charging scenarios present a particular challenge due to the complex current control strategies that strongly influence cell temperature distribution, making thermal uniformity a key concern. This study presents a coupled electrochemical-thermal simulation framework based on the DCiR (direct current internal resistance) model to examine heat generation and temperature responses during fast charging. The model incorporates heat conduction pathways and the structural layout of the module, enabling the evaluation of thermal mismatch risks and the optimization of module design and charging strategies. The findings offer practical insights for battery thermal management and the development of advanced fast-charging strategies.
Xiao, Fangzhi, CHEN, Guijie, ma, Shihu, Hu, Xiao, SONG, Shujun, Wakale, Anil Bhaurao
Novel SOH Estimation Using the Differential Force Signal for Li-ion Batteries under Constraint Conditions2026-01-0388To be published on 04/07/2026
Accurate estimation of the State of Health (SOH) is crucial for ensuring the safety and reliability of lithium-ion batteries. Compared to conventional electrical signals, battery swelling behavior offers significant advantages as it contains richer aging-related information. This study investigates the aging characteristics of batteries under external mechanical constraints, and proposes an innovative SOH estimation method based on differential force (DFDV) analysis. Cycling tests were conducted on fully constrained LFP prismatic batteries under 0.2 MPa. Throughout the testing, both mechanical and electrical signals were synchronously monitored and recorded. The research systematically analyzes the swelling behavior and aging patterns of batteries. Through incremental capacity analysis (ICA), the aging behavior and underlying mechanisms under room-temperature and constrained conditions were revealed. Simultaneously, mechanical signal analysis demonstrated a strong correlation between
Niu, Zhice, ZHANG, Shan, Xia, Yong
Thermal Performance of Natural Fiber Hybrid Composites for Automotive Insulation Applications2026-01-0244To be published on 04/07/2026
This study investigates the thermal conductivity of natural-fiber-based hybrid polymer composites with potential automotive insulation applications. With the increasing demand for lightweight, sustainable, and thermally efficient materials in vehicle cabins, under-hood systems, and electric vehicle battery enclosures, natural fiber composites present a promising alternative to conventional glass-fiber composites. Three distinct composite configurations were fabricated: pure glass, glass-jute hybrid, and glass-jute-coir hybrid, using general-purpose polyester resin as the matrix. The composites were manufactured using the hand lay-up method. Thermal conductivity measurements were conducted using the ASTM C177 guarded hotplate method on composite plates. Results indicate that the hybrid composite with glass, jute, and coir fibres has the lowest thermal conductivity, making it the most effective for insulation applications. This study demonstrates that natural fibre-reinforced composites
Mache, Ashok, Salve, Aniket, Chinchanikar, Satish, Borse, Hardik, Deshmukh, Omkar, Mahadikpatil, Siddhi, Kulkarni, Aparna
Towards Plating-Free Charging: Lightweight Prediction of Lithium Plating Current Limits2026-01-0387To be published on 04/07/2026
Lithium plating is a critical barrier to fast charging in electric and hybrid-electric vehicles, occurring at high state of charge (SOC) or low temperatures when Li⁺ deposits as metallic lithium on the anode surface instead of intercalating into graphite. At low temperatures, plated lithium may form dendrites that pierce the separator and trigger thermal runaway, while at high SOC, irreversible plating accelerates capacity fade by depleting cyclable lithium. Despite extensive study, lithium plating remains difficult to incorporate into battery management systems (BMS) due to computational complexity and the challenge of real-time detection, leading to reliance on conservative lookup maps. This work presents a lightweight empirical model for predicting plating-free charging limits in lithium nickel manganese cobalt (NMC) cells. A high-fidelity pseudo-2D electrochemical model was exercised across a wide range of charge rates and temperatures to capture the coupled effects of SOC
Sundar, Anirudh, Ghate, Atharva, Zhu, Qilun, Prucka, Robert, Barron, Morgan, Figueroa-Santos, Miriam
Method of Estimating Electric Vehicle Charge Time Based on Neural Networks2026-01-0382To be published on 04/07/2026
Accurate prediction of electric vehicle charging time is critically hindered by dynamic, non-linear factors including battery aging which is indicated by the State of Health (SOH), substantial power diversion to thermal management systems in extreme temperatures, fluctuating user-defined accessory loads, and hardware limitations of the charging infrastructure. Traditional estimation methods, reliant on static models or predefined calibrations, fail to adapt to these real-world variables, leading to inaccurate predictions and user dissatisfaction. This paper presents a novel data-driven estimation framework utilizing a tailored feedforward neural network architecture specifically designed for this complex task. The model processes a sensitive set of inputs—including initial State of Charge (SOC), SOH, battery temperature, charging station power level and user-selected target SOC—to effectively capture the intricate, non-linear interdependencies governing the charging process. The
Xie, Zhentao, shojaei, Sina, Weslati, Feisel
Electrified Propulsion System Balancing for Light Duty Full Size Truck and Sport Utility Vehicles: A 2026 North American Market Perspective2026-01-0412To be published on 04/07/2026
Achieving the stringent EPA CAFE 2032 standards for light-duty full-size trucks and SUVs in North American poses significant challenges. While Battery Electric Vehicles (BEVs) offer a clear path to zero tailpipe emissions, their widespread adoption in this segment faces hurdles including range anxiety, payload/towing capabilities, and traditional truck/SUV use cases. This paper investigates a balanced approach, focusing on optimizing propulsion system design with appropriate hardware content, can effectively meet future fuel economy and emissions standards. This investigation examines advanced BEVs and hybrid electric vehicle architectures, including full hybrids (HEVs), and plug-in hybrids (PHEVs) tailored for full-size trucks and SUVs. Considerations include the optimal sizing of internal combustion engines, electric motors, and battery packs to deliver robust performance while maximizing energy efficiency. This paper analyzes the integration of technologies such as electrified
Babcock, Dillon, Robinette, Darrell
Thermal Finite Element Modelling and Prediction of Laser Welded Battery Packs2026-01-0385To be published on 04/07/2026
Battery modules consist of battery cells electrically joined at the terminals by conductive busbars. Laser welds are the most consistent and controllable process to create these connections on a large scale due to their control over power, laser width, speed, wobble, and overlap, and their quality is critical to battery pack performance. Tuning these parameters for an application typically requires weld trials to reach desired weld width, penetration, and strength without overheating the battery cell and weakening the dielectric insulators around the terminals. Poorly welded cells in a module can result in increased electrical resistance, causing greater joule heating and accelerated cell aging, and poorly welded modules can lead to uneven aging and unpredictable performance. To better understand the laser welding process, a modelling approach was developed to predict weld properties to reduce production time, costs, and potential cell damage. The 3D finite element model was calibrated
Contreras, Luis, Hoffmeyer, Matthew, Abidin, Zainal
Physical Test Validated Multi-level Power Electronics for Next-generation Electrified Vehicles Charging & Efficiency Improvement2026-01-0435To be published on 04/07/2026
Improving the energy efficiency of electrified vehicles remains a central objective in modern electric powertrains. Multi-level converters (MLCs) are widely recognised for lowering conversion losses relative to two-level inverters and improving total harmonic distortion (THD) in the sinusoidal supply to motors with a consequent reduction in motor losses. Despite this, sustained production-oriented validation at the integrated system level remains limited. This work introduces a multi-level converter architecture of the Battery Integrated Modular Multi-Level Converter (BIMMC) topology using Cascaded H-Bridge (CHB) architecture. It offers improvements in all key metrics of performance, cost, package size, mass and robustness compared to the current state-of-the-art two-level inverter system with distributed functions for charging available in the market today. The overall solution is highly functionally integrated. It supports four major functions required in electric vehicles without
Bao, Ran, Kalaiselvan, Prashanth, Rener, Kristof, Hallam, Philip, Shi PhD, Kai, Yue, William, Ma, He, Grimshaw, Andrew, Patel, Simon
In-Use Life Digital Twin and Swappable Use Case for Battery Durability2026-01-0397To be published on 04/07/2026
In-Use Life Digital Twin and Swappable Use Case for Battery Durability By: Patricia Laskowsky, Josue Albarran, Justin Bunnell, and Andrew Zettel Abstract The UN GTR 22 is required as part of the Environmental Protection Agency’s legislative rulemaking for multi-pollutants emission standards for model years 2027 and later light-duty and medium duty vehicles. The EPA claims it has the right to govern requirements on ZEVs and BEVs. ZEVs, in their viewpoint, are “emission related” because it enables the vehicle to produce zero emissions. With the adoption by the EPA under its Tier 4 regulations of the UN GTR 22, comes several new tracking DIDs, Data Identifiers. These DIDs are tied battery durability and energy tracking They track conditions and usages of electric vehicles that may accelerate the loss of electric range and/or loss of efficiency of the propulsion energy storage and delivery. More specifically, tying these trackers to EPA emission related discussion, the loss of electric
Laskowsky, Patricia, Bunnell, Justin, Zettel, Andrew, Albarran, Josue
A CFD Based Multi-Physics Modeling Approach to Predict Vent Gas Flow Paths due to Can Melting during Prismatic Cell Thermal Runaway2026-01-0407To be published on 04/07/2026
As the automotive industry increasingly adopts high-energy-density pouch cells, ensuring vehicle safety against catastrophic thermal runaway (TR) has become paramount. Predicting the complex failure sequence of pouch cells, requires high-fidelity simulation tools that can capture tightly coupled physical phenomena. This paper presents a comprehensive, three-dimensional multi-physics Computational Fluid Dynamics (CFD) framework designed to simulate the entire TR event. The simulation originates with a multi-step Arrhenius chemical kinetics model to calculate the heat and gas generated by the primary exothermic reactions. This process drives a rapid increase in internal temperature and pressure, which is resolved by the model’s fluid dynamics solver. The initial vent opening is triggered when this internal pressure exceeds a predefined mechanical burst threshold, simulating a realistic seal rupture. Concurrently, a Conjugate Heat Transfer (CHT) analysis calculates the temperature
Mukherjee, Swarnava, Schlautman, Jeff, Srinivasan, Chiranth
Behavioral Determinants of Electric Vehicle Battery Degradation: Evidence from Large-Scale Real-world Operations2026-01-0458To be published on 04/07/2026
Electric vehicles (EVs) are central to sustainable transport, yet battery service life remains a limiting factor for cost and adoption. Distinct from traditional laboratory-based simulations that often fail to capture the complexity of field conditions, this study investigates how EV user behavior—including driving style and charging demands—influences capacity using large-scale, real-world operational data from daily EV usage. A data-driven framework is developed to quantify driving and charging behaviors through multidimensional feature extraction at the vehicle level and estimate battery State-of-Health (SOH) trajectories, enabling direct linkage between individual behavior patterns and degradation outcomes. Results reveal substantial heterogeneity in aging rates explicitly driven by diverse user behaviors: under identical urban conditions, vehicles with a radical driving style exhibit approximately 81% faster SOH decline per 20,000 km than those with a moderate style ; regarding
Liu, Tianyi, Jing, Hao, Zhu, Jiankuan, Chen, Yongjian, Ou, Shiqi(Shawn), Qian, Xiaodong
A Novel Power-Split Hybrid Electric Architecture for Off-Road Tracked Vehicles: Design and Performance Evaluation.2026-01-0258To be published on 04/07/2026
Tracked off-road vehicles operate at low speeds with high tractive effort and frequent skid-steer maneuvers, conditions that push torque and power demand to extremes and exacerbate powertrain efficiency losses. Electrification can improve energy conversion and mobility for such duty cycles. This paper introduces a novel power-split hybrid electric architecture for a tracked vehicle and benchmarks it against three designs: a conventional mechanical driveline, a series hybrid, and a P2 parallel hybrid. To enable fair, architecture-agnostic comparisons, a supervisory controller based on Stochastic Dynamic Programming (SDP) schedules engine operation and power flow across all layouts under representative off-road scenarios, including skid-steer events, with varying terrain and power-demand profiles. Results show higher energy conversion efficiency (lower fuel use) for the proposed power-split architecture, followed by the parallel, then series, and lastly conventional configuration across
Ghate, Atharva, Sundar, Anirudh, Zhu, Qilun, Prucka, Robert, Figueroa-Santos, Miriam, Barron, Morgan, Castanier, Matthew P.
Mechanical Properties of Elastomeric Foam-Based Compression Pads for Battery Pack Applications2026-01-0247To be published on 04/07/2026
With the increasing adoption of electric vehicles (EVs) worldwide, ensuring the long-term reliability and performance of the battery systems has become a paramount engineering challenge. Lithium-ion cells exhibit dimensional changes throughout their operational life, characterized by reversible “breathing”—expansion and contraction during charge and discharge cycles—and irreversible swelling due to aging. Compression pads are critical components for ensuring the lifetime performance of battery packs. The primary function of a compression pad is to act as a compliant cushion between cells. It accommodates these volumetric fluctuations by exerting consistent and optimized pressure. By absorbing the stress from cell expansion and maintaining structural integrity within the module, compression pads mitigate degradation mechanisms and ultimately maximize the durability and safety of the battery system over thousands of cycles. This paper highlights the importance of tailoring elastomeric
Deng, Weilin, Gunashekar, Subhashini
Plug-in Electric Vehicles Adoption: A Review of Forecasting Methodologies, Policy Impacts, and Future Trajectories in Major Global Markets2026-01-0455To be published on 04/07/2026
Accurate forecasting of Plug-in Electric Vehicle (PEV) market sales share is vital for evidence-based policymaking, yet existing studies employ diverse and often fragmented methodologies, creating a need for systematic review to clarify their analytical foundations and comparative strengths. This study classifies mainstream forecasting methodologies into theory-driven and data-driven approaches, providing a review of five representative models' merits, limitations, and potential directions. Analysis reveals that leading approaches increasingly employ cross-scale model coupling, theory-data fusion, and modular design to harness complementary strengths, improving model robustness and predictive accuracy. Furthermore, the study compares PEV policies and market forecasts in China, the United States, and Europe—the world's three largest automotive markets. The findings indicate a strong linkage between forecast convergence and policy stability. China demonstrates the highest policy
Luo, Wei, Ou, Shiqi(Shawn), Zhou, Pan, Wang, Tianpeng, Qian, Xiaodong
Identifying pressure drop and heat transfer correlations for a liquid-cooled lithium-ion battery pack model of electric vehicles under hot-cold driving2026-01-0394To be published on 04/07/2026
The performance of a full lithium-ion battery (LIB) pack with its cooling system depends on the pressure drop and heat transfer from the cell to ambient air through coolant, cooling flow channels, air gaps, and pack cases. Predicting the LIB pack responses (i.e: voltage, SOC, temperature) requires accurate predictions of the thermal performance between the cells and ambient air and cooling flow behaviour inside the pack, respectively, since the pack has several thousand cells, cooling channels, and channel pipe bends. This work presents a systematic approach to identifying heat transfer and pressure drop ∆P correlations that capture the real-time thermal-electrical performance of a mass-produced LIB pack under constant speed (in winter) and transient driving (in summer). A vehicle test is conducted using a Tesla Model Y, a long-range, dual-motor model equipped with a 75-kWh LIB pack. The LIB pack's thermal and electrical performance is recorded under both constant speed and transient
Sok, Ratnak, Kusaka, Jin
Operational Feasibility of Battery Swapping in U.S. Transit: A Case Study of King County Metro2026-01-0402To be published on 04/07/2026
Battery swapping technology has emerged as a promising alternative to conventional plug-in charging for electric bus fleets, offering rapid turnaround times and improved vehicle availability. This paper investigates whether battery swapping can be integrated into U.S. public transit bus operations without disrupting existing timetables. A Seattle based public transit agency- King County Metro is taken as a case study in this paper. Using General Transit Feed Specification data from King County Metro, a MATLAB model was built that reconstructs blocks and layovers, extracts dwell-time opportunities, and performs block distance and block time analyses to understand operational rhythms. A mathematical energy model was developed that maps route mileage, efficiency, and layover availability to swap decisions, using a look-ahead rule that defers exchanges whenever the next feasible layover can still be reached while respecting a minimum state-of-charge. The workflow estimates how many swaps
Vadlapatla, Taraka Rishi, Jankord, Gregory, D'Arpino, Matilde
Effects of Obstacle Height and Vehicle Roll Behavior on Electric Vehicle Side Impact Safety2026-01-0405To be published on 04/07/2026
Electric vehicles (EVs) face unique safety challenges under pole side impact conditions, largely due to the presence of floor-mounted battery packs. Existing regulatory test procedures, such as Federal Motor Vehicle Safety Standards (FMVSS) 201, primarily address occupant injury using full-height cylindrical obstacles. These procedures were originally developed for internal combustion vehicles (ICVs). However, real-world roadside crashes frequently involve obstacles of varying heights, such as guardrails, curbs, and median bases. While these obstacles pose limited risk to the passenger compartment, they can intrude into the battery pack and trigger thermal runaway. This study investigates the influence of obstacle height on EV pole side impacts. Finite element simulations of a commercially available sedan were conducted against rigid obstacles of different heights. Results reveal a non-monotonic trend of battery intrusion governed by the interplay between rollover dynamics and
Ma, Chenghao, Xing, Bobin, Zhou, Qing, Xia, Yong
Adhesion Strength of Coatings in Battery Structural Joints2026-01-0238To be published on 04/07/2026
In the design of Rechargeable Energy Storage System (RESS) structures, including battery trays, module side plates, and end plates, there are multiple conflating factors, including: Mechanical requirements necessitating the use of electrically conductive materials (steel and aluminum); proximity between battery module structure and battery cells, necessitating the use of electrical isolation coatings; and module and pack designs that retain cells via the use of Structural Adhesive Material (SAM). Inherently, with this design approach, organic coatings are placed in a new and perilous position. In a sense, the coating becomes a supplement to an adhesive. As virtual analysis tools have become more sophisticated, there is increasing reliance on these tools to predict the occurrence of structural failures in various load cases. Factors in test method, paint pretreatment, and topcoat affecting adhesion of organic coatings in structural adhesive joints are discussed, including: Adhesive
Moceri, Charles, Harper, Jared
Modeling the Battery Supply Chain for Traceability: A Proof of Concept for SAE J33272026-01-0379To be published on 04/07/2026
This presentation centers on a proof of concept of SAE J3327, a standard for creating a digital traceability record for electric vehicle (EV) batteries. The presenters have been leading the development of the standard, which harmonizes with the European Union’s Digital Product Passport for batteries. It establishes a consistent vocabulary and procedure for creating a digital record of important battery information including critical mineral sourcing, processing and manufacturing of cells and packs. The standard has a publication date of fourth quarter, 2025 and will be accompanied by this technical paper. The paper guides users through mapping the battery supply chain, which is characterized by complexity: multiple locations, mixing of materials, numerous processing and manufacturing steps.
Menchaca, Frank
Electrochemical-Thermal Simulation for Evaluating Indirect and Immersion Cooling in High-Power EV Charging2026-01-0403To be published on 04/07/2026
With the rapid advancement of electric vehicle (EV) fast-charging technology, battery thermal management faces increasingly critical challenges due to elevated heat generation and stringent safety requirements. Immersion cooling has emerged as a promising solution because of its superior heat dissipation and uniform temperature distribution compared to conventional indirect cooling methods. This study develops an electro-thermal coupled simulation framework for evaluating indirect and immersion cooling performance under high-power charging conditions. A pseudo-two-dimensional (P2D) electrochemical battery model of an electric vehicle was developed in GT-Suite and validated against vehicle on-board charging data. In parallel, an immersion cooling system model was developed and validated using battery bench test results. This model was subsequently integrated into the vehicle model to allow comparisons with a conventional indirect cooling system under high-power DC fast-charging scenario
Guo, Yuyang, Rockstroh, Toby, Haenel, Patrick, Oezdag, Erdal, Bodemann, Basil, Toghyani PhD, Somayeh
Simplified Thermal Runaway Propagation Modeling to Enable Mass-Optimized Battery Pack Design2026-01-0404To be published on 04/07/2026
This paper presents a simplified approach to model thermal runaway propagation in a multi-cell battery pack, with the goal of designing a safe and lightweight pack for mass-sensitive applications. The key parameters which characterize single-cell thermal runaway, including heat release profile, apparent cell emissivity and mass loss, were extracted from empirical nail penetration tests. This characterization was used to drive a three-dimensional thermal model of a 19-cell hexagonal sub-pack with a center trigger cell. To enable rapid design exploration, a symmetry-based computationally simplified domain was used for a full-factorial Design of Experiments (DOE) varying cell spacing, epoxy thickness, heat spreader thickness, and cup geometry. The DOE results were used to identify dominant heat-transfer mechanisms, capture main and interaction effects, and determine mass-efficient design levers governing peak-neighbor cell temperature during propagation. Insights from the DOE study
Kalyankar, Apoorv, Owen, Elliot, Strohmaier, Kyle, Mardall, Joseph
Assessing Energy Use, Cost, and Emissions of Small Regional Rail Vehicles: Methodology and Case Study on a German Track2026-01-0419To be published on 04/07/2026
The decarbonization of regional rail remains a pressing challenge in the European Union, where nearly half of the 200,000 km network remains unelectrified. Lightweight, single-car railbuses historically provided efficient service on such lines, but modern replacements are scarce. This work evaluates a standardized 30-ton, 16 m railbus platform for unelectrified regional service, focusing on propulsion system design and trade-offs between range, cost, and emissions. A MATLAB/Simulink drive-cycle model was developed to simulate energy consumption under realistic operating conditions. The Erfurt–Rennsteig route in Germany (130 km round trip, gradients up to 6 %) was selected as a representative case study. The model incorporates sub-models for traction motors, lithium-ion batteries (LFP and LTO), fuel storage, fuel cells, and ICE gensets across multiple fuel options (diesel, gasoline, methane, ethanol, methanol, HVO, FAME, and hydrogen). Battery lifetime is estimated using a combined
Ahrling, Christoffer, Tuner, Martin, Gainey, Brian, Torkiharchegani, Amir, Scharmach, Marcel, Hertel, Benedikt, ALAKÜLA, Mats
Protection of Megawatt-Scale DC Charging Infrastructure for Heavy Duty Vehicles: A Review of Current Technologies and Future Roadmap2026-01-0400To be published on 04/07/2026
Abstract Direct Current (DC) fast charging enables the direct delivery of megawatt (MW) scale power to the large battery systems of heavy-duty electric vehicles (EVs), such as trucks, buses, and construction machinery. This contrasts with Alternating Current (AC) charging, which is constrained by the limited capacity of onboard chargers. The feasibility of ultra-fast DC charging has been driven by advancements in semiconductor technology offering higher voltage and current handling capabilities as well as improvements in battery energy density. Ongoing research indicates continued growth in both semiconductor power handling and battery storage capacity, further strengthening the case for ultra-fast DC charging. Key benefits include significantly higher charging efficiency, drastically reduced charging times, and lower driver fatigue. However, unlike AC systems, DC charging infrastructure presents unique protection challenges. These challenges arise from the rapid rise of DC fault
Rahman, Md Rakib-Ur, Dobrzynski, Daniel
CFD Modelling of Cell Formation Gas and Venting During the EV’s Battery Manufacturing Process2026-01-0384To be published on 04/07/2026
The electric battery is a critical component of electric vehicles (EVs), where high power demands pose significant operational challenges. One such challenge is gas generation within the porous anode layer, which can lead to pressure buildup inside the battery. The complex interfacial dynamics at the microscale play a crucial role in determining the effectiveness of gas venting and the resulting pressure evolution. This study addresses this issue through a two-pronged simulation approach. First, gas generation within a representative anode microstructure is investigated using a Volume of Fluid (VOF) framework that resolves tortuous flow passages. The simulations reveal that gas generation in such microstructures can lead to pressure rises of several thousand Pascals, with interfacial behavior primarily governed by surface tension effects. Second, a high-level battery pack simulation is performed using a porous media approach to evaluate system-scale gas venting and localized
Mahyawansi, Pratik J., Schlautman, Jeff, Viswanath, Priyanka, Srinivasan, Chiranth
A Comprehensive Modelling tool for Heavy-Duty Hybrid Fuel Cell/Battery Powertrains2026-01-0430To be published on 04/07/2026
The global transition towards sustainable transportation is driving the development of efficient, low-emission propulsion systems. Battery-electric solutions are effective in urban contexts but face limitations in heavy-duty and long-haul applications due to the size and weight of the required energy storage. Hybrid battery/fuel cell powertrains offer a promising alternative for such use case, reducing vehicle mass and charging times while maintaining high energy efficiency. This study presents a zero-dimensional MATLAB/Simulink model of a parallel hybrid fuel cell/battery system for heavy-duty vehicles. The model encompasses the main vehicle subsystems, including the fuel cell stack with auxiliaries, the battery pack, the electric drive, the transmission and vehicle longitudinal dynamics, coordinated through a rule-based energy management strategy. Two representative vehicle configurations were analysed: a Group 2 urban delivery vehicle, and a Group 5 long-haul truck. Model validation
Montecchi, Gianluca, Martoccia, Lorenzo, D'Adamo, Alessandro
Advanced Integrated Chassis Control for Improved Energy Efficiency and Driving Experience in Electric Vehicle Applications2026-01-0643To be published on 04/07/2026
Complexity of modern ground vehicles grows constantly, since car manufacturers want to provide functionality, while customers are expecting innovation and recent technologies to be integrated into the latest models released to the market. Recent advances in hard- and software opened the gates for new means of vehicle control and operation. Especially the transition to electric propulsion systems and decoupled chassis actuators offer completely new opportunities of dynamics control and manipulation. This paper presents an approach for integrated chassis and vehicle motion control in (battery) electric vehicle applications by using new and innovative controllers as well as mechatronic chassis systems. In several experiments on public roads with a fully instrumented vehicle demonstrator, that features in-wheel based rear-wheel drive and a hybrid brake-by-wire-system, the proposed control is tested under real environmental and traffic conditions with respect to aspects like energy
Heydrich, Marius, Mitsching, Thomas, Ivanov, Valentin
Novel Steel Tubular Side Sill Reinforcement Design and Validation for Enhanced Crash Performance in EVs2026-01-0478To be published on 04/07/2026
Increased use of Electrical vehicles (EVs) brings in unique structural design challenges particularly in Side Impact scenarios when the battery pack is near the sill region therefore elevating the possibility of Electrical Module penetration and triggering thermal runway event resulting from the crash. Thus, Electric Vehicles present unique structural design challenges. This study intends to evaluate a novel tubular structure design for side sill reinforcement and its performance benefits over a traditional aluminum side sill reinforcement currently commonly utilized for battery protection in EV vehicles body components. The proposed Steel side sill design mainly focuses on structural rigidity and improved load transfer during side pole impact crash cases and address manufacturing complexity and cost reduction opportunity. Multiple iterations for Steel side sill reinforcement design were carried out using finite element analysis with software like LSDYNA Hyper works to propose optimal
Kusnoorkar, Harsha, Khutorsky, Alex, Penumetsa, Vivek, Koraddi, Basavaraj
Study on performance parameters of retarder in mountain condition of hybrid electric vehicle2026-01-0617To be published on 04/07/2026
In mountain driving scenarios, the continuous braking demands of vehicles pose significant challenges to the performance and reliability of braking systems. Traditional fuel-powered vehicles primarily rely on friction brakes for deceleration, which face issues such as high thermal fade risks and severe brake wear. While pure electric vehicles can utilize motor energy recovery to provide braking force and recover energy, their braking capacity is limited by the maximum regenerative torque of the motor. Moreover, when the battery State of Charge (SOC) is high, the energy recovery function may be restricted or disabled to protect the battery, leading to a sharp reduction or complete loss of braking torque—a safety hazard. Range-extended hybrid vehicles combine the advantages of both engine and electric drive systems. During long downhill operations, their motors can also serve as priority decelerators for efficient energy recovery. However, similar to pure electric vehicles, their motor
duan, xianqi, Tan, Gangfeng, Li, LiuYuanHeng, Tian, Tian, Yang, Yong
Advancing Sustainable Electric Vehicles: A Simulation-Driven Study on Rare Earth-Free Motors and Battery Technologies2026-01-0242To be published on 04/07/2026
As electric vehicles (EVs) become more popular, the growing dependence on rare earth materials in their motors and batteries has raised concerns about supply risks, environmental impact, and rising costs. Finding alternatives to these materials is essential to making EVs more sustainable and affordable for everyone. This study aims to explore new motor designs and battery chemistries that reduce or eliminate the use of rare earth elements. We will focus on promising options like induction and wound rotor motors, as well as ferrite and iron-nitride magnets that can replace traditional rare earth magnets in EVs. On the battery side, we will look at lithium-iron-phosphate (LFP) and sodium-ion batteries, which offer a safer and more cost-effective alternative while maintaining good performance. A big part of this work involves using advanced simulations to predict how these new materials and designs will perform. This lets us optimize the components before building physical prototypes
Saraswat, Shubham, Vishe, Prashant
Low-voltage electric vehicle with increased electrical safety and distributed charging system2026-01-0396To be published on 04/07/2026
Abstract - Reducing the high-voltage BEV to a household level of 120-240 volts is considered in the article as an effective means of solving the problems of electrical safety, maintenance and minor repairs of an electric vehicle in household conditions, distributed power supply of BEV with walking distance for the driver. The analysis of the low-voltage electric drive is performed under the assumption that the battery has a nominal voltage of 200 volts. The issues of transforming a high-voltage machine (400 volts) into a low-voltage one (200 volts) by switching the stator phase sections from serial to parallel connection without changing the overall and energy characteristics are considered. It is shown that a two-motor unit with induction machines with a capacity of 50 kilowatts can provide 100 kilowatts in long-term and up to 200 kilowatts in peak modes. The article considers the issues of implementing a low-voltage inverter and modern trends in distributed power supply for BEVs
Smolin PhD, Victor, Sobolevskiy, Anatoliy, Volovich, Georgy
Advancing Safe Battery Design through Experimental Cell Characterization of Thermal, Electrical and Mechanical Properties2026-01-0408To be published on 04/07/2026
Lithium-ion batteries are critical to electric vehicles and grid-scale energy storage. Safe design of battery systems relies on accurate simulation of battery thermal runaway under electrical, thermal, and mechanical abuse. A predictive battery simulation requires the characterization of electrical, thermal, and mechanical properties of the battery at the full cell and cell-component levels. In this study, a commercial cell from an electric vehicle was disassembled, and testing was conducted to support both homogenized and detailed computational models. At the cell level, electrical properties were characterized using Hybrid Pulse Power Characterization (HPPC) testing to assess the cell power capability. Cell punch tests were conducted to characterize mechanical behavior under deformation. These tests were used to develop a multi-physics homogenized cell model. On the other hand, detailed cell modeling that includes different component layers could help users understand localized cell
Challa, Vidyu, Rostami-Angas, Masoud, kong, Kevin, Wang, Leyu, Reichert, Rudolf, Kan, Cing-Dao
Techno-economic assessment of battery recycling and cascade use for legal and illegal recyclers in China2026-01-0456To be published on 04/07/2026
With the rapid popularization of electric vehicles (EVs), the battery recycling industry is undergoing rapid growth. While the Chinese government has implemented a white-list mechanism under which only approved recyclers are allowed to process retired batteries, the presence of small-scale illegal battery recycling vendors has posed challenges to this mechanism. This study compares the techno-economic performance of battery recycling between legal and illegal recyclers in China, and discusses strategies to eliminate illegal operations. Our research covers two battery chemistries: lithium nickel-manganese-cobalt oxide (NMC) and lithium iron phosphate (LFP), as well as two technological pathways: resource recycling and cascade utilization. Under the base case, the costs of illegal vendors are 35-46% lower than that of legal companies. Although legal companies achieve high resource utilization, their overall economic performance lags behind due to their high costs associated with
Du, Shilong, Li, Haoyang, Dou, Hao, Hao, Han
Dual Battery Pack System for Multi-Voltage Electric Vehicle Operation2026-01-0392To be published on 04/07/2026
Electric Vehicles (EV) have become a major focus in the automotive industry. This paper introduces a propulsion system design, which supports the Wide Torque Band (WTB) concept to boost the power density of PM (permanent magnet) motors in EV Trucks resulting in performance, efficiency, and cost benefits. The WTB drive requires an 800V battery for vehicle operation. The chosen solution combines two 400V battery packs to create a selectable 400V/800V DC bus. The electrical hardware and controls to manage the dual battery packs in either series (800V) or parallel (400V) mode are presented in this paper. A prototype battery management system (BMS) along with existing production Voltage, Current, Temperature Monitoring (VITM) hardware are applied to perform mode switching, safety, and cell balancing. The success of this dual pack hardware enables high voltage dynamometer testing of a new 800V DU (Drive Unit) and inverters for EVs. The flexibility of switching between two voltage levels (400
Zhu, Yongjie, Lee, Chunhao, Gopalakrishnan, Suresh, Namuduri, Chandra
Ambient and Initial Temperature Effects on Battery Electric Vehicle (BEV) Range and Energy Consumption Rate Modeled in FASTSim2026-01-0277To be published on 04/07/2026
Ambient and initial temperatures have a significant impact on the energy consumption rate of battery electric vehicles (BEVs) due to auxiliary loads and the dependence of battery efficiency on temperature. Quantifying these impacts can help BEV owners, communities, and researchers understand and prepare for the impact of temperature on BEV vehicles, especially as adoption increases. We used NREL's FASTSim 3 to investigate the impacts of a two-dimensional design-of-experiment that swept ambient and initial temperature in simulating a compact BEV hatchback over UDDS (city) and HWFET (highway) US EPA drive cycles. Compared to a 22 ° C ("cozy") initial / ambient temperature baseline in UDDS, a cold initial / cold ambient temperature (-7 ° C) resulted in a 221% increase in the energy consumption rate, a cozy initial / cold ambient temperature resulted in a 94% increase, a hot initial (45 ° C) / hot ambient (40 ° C) temperature resulted in a 40% increase, and a cozy initial / hot ambient
Baker, Chad, Steuteville, Robin, Holden, Jake, Gonder, Jeffrey, Carow, Kyle
Development of a virtual test rig to evaluate thermal management of a battery-electric vehicle under battery heating-cooling modes2026-01-0416To be published on 04/07/2026
A battery-electric vehicle (BEV) has multiple powertrain components (battery, inverter, e-motor), a thermal management system (compressor, heat exchanger, cabin heating, ventilation, and air-conditioning), and a vehicle body, among others. Vehicle testing is time-consuming, and also changing powertrain components during the testing and design process is costly. Simulation models (aka virtual or simulation test rig) have been widely used for efficient vehicle design. This work presents a systematic approach to developing a virtual test rig to evaluate the thermal performance of battery-electric vehicles. A Tesla Model Y is tested in a chassis dynamometer, and the measured vehicle performance data are used as boundary conditions for the complete vehicle model. The detailed lithium-ion battery (LIB) pack model, including its cooling system, was developed and calibrated using various transient driving cycle data. The HVAC model uses a simplified controller to maintain the cabin temperature
Sok, Ratnak, Kusaka, Jin
Improving Winter Driving Range of EVs with a Novel Desiccant Device: Ceramic Humidity Regulator (CHR)2026-01-0117To be published on 04/07/2026
With Rapid growth of Electric Vehicles (EVs) in the market, challenges such as driving range, charging infrastructure, and reducing charging time needs to be addressed. Unlike traditional Internal combustion vehicles, EVs have limited heating sources and primarily uses electricity from the running battery, which reduces driving range. Additionally, during winter operation, it is necessary to prevent window fogging to ensure better visibility, which requires introducing cold outside air into the cabin. This significantly increases the energy consumption for heating and the driving range can be reduced to half of the normal range. This study introduces the Ceramic Humidity Regulator (CHR), a compact and energy-efficient device developed to address driving range improvement. The CHR uses a desiccant system to dehumidify the cabin, which can prevent window fogging without introducing cold outside air, thereby reducing heating energy consumption. CHR is based on desiccant dehumidification
Sakai, Naoki, Takahiko, Nakatani, Shinoda, Narimasa, Ihara, Yukio, Wakida, Norihiro, Kato, Kyohei, Anoop, Reghunathan-Nair
Standalone Battery Pack Thermal Behavior Simulation and Experimental Correlation in a Controlled Environment2026-01-0125To be published on 04/07/2026
Battery thermal management is crucial for ensuring the safety, efficiency, and longevity of lithium-ion battery packs, particularly in electric vehicles (EVs). The primary purpose of a lithium-ion battery in an electric vehicle is to store and provide electrical energy for vehicle propulsion while maintaining safety under different operating conditions. This work proposes a thermal correlation between 1D CFD simulation and experimental test data under passive environmental heat exchange conditions without active coolant flow of a battery pack comprising four modules. An environmental exchange test was conducted using a 50% state of charge (SOC) battery pack, which is stabilized at 25°C to assess passive heat dissipation, thermal soak behavior, temperature distribution, and potential thermal runaway risks. The simulation predictions correlate well within a 1.5°C range compared to test results using ambient temperature and flow inputs, which confirms the reliability of the modeling
Nayaka, Sateesh Kumar, Dixit, Manish, Gudiyella, Soumya
Simulation of Conjugate Heat Transfer using the Lattice Boltzmann Method2026-01-0135To be published on 04/07/2026
Flow simulation with conjugate heat transfer, which involves fluid flow, conduction, and radiation in solid components, is a critical capability that helps engineers design and evaluate cooling systems for heat-generating components such as brakes, powertrains, batteries, and power electronics for both gasoline and electric vehicles. For this study, we utilize PowerFLOW™, featuring its novel native thermal solver, which models both fluid and solid domains within a single model. For the flow domain, we use the Lattice Boltzmann Method with VLES turbulence modeling based on the RNG k-epsilon method. And for the solid domain, the finite volume method with second-order accuracy for thermal conduction and a surface-to-surface radiation for the surfaces. This approach not only leads to a more integrated and streamlined workflow but also enables an accurate modeling of conduction and radiation. In this study, we demonstrate the accuracy of the conjugate heat transfer simulation methodology
Mukutmoni, Devadatta, Shock, Richard, Li, Han, Wanderer, John
Energy-Efficient Predictive Cruise Control in Heavy-Duty Electric Trucks with Optimization of the Penalty Factor as a Function of Payload2026-01-0042To be published on 04/07/2026
Heavy-duty Class 8 battery electric trucks not only offer a significant reduction in greenhouse gas (GHG) emissions compared to conventional diesel trucks but can also provide significant savings in fuel costs. To further enhance the energy and freight efficiency, Predictive Cruise Control (PCC) algorithms can be developed that generate optimal acceleration profiles for the vehicle by minimizing a cost function which combines both energy consumption and deviation from the desired velocity. A critical component of the cost function is the penalty factor, which governs the trade-off between energy use and travel time, which are two conflicting objectives in freight logistics. Selecting an appropriate penalty factor is essential, as freight deliveries are time-sensitive but minimizing energy consumption remains a priority. Moreover, variations in payload significantly affect vehicle dynamics and energy usage, making it critical to adapt the penalty factor to different payload conditions
Safder, Ahmad Hussain, Villani, Manfredi, Wang, Eric, Khuntia, Satvik, Nelson, James, Meijer, Maarten, Ahmed, Qadeer
Understanding the Effects of Process Parameters on the Dispense Uniformity of Elastomeric Silicone Coating Material for Automotive Manufacturing.2026-01-0239To be published on 04/07/2026
As electric vehicle (EV) manufacturing scales, innovative approaches have been evolving for battery fire protection materials to mitigate thermal runaway hazards, including fire and blast protective coatings. These materials often exhibit high-viscosity and must be deposited with uniform thickness and stable geometry to ensure reliable thermal barriers and battery pack integration. In practice, coating uniformity (uniform thickness, edge fidelity, and minimal sag/run prior to cure) is highly sensitive to dispense conditions, including nozzle slot width, nozzle length, effective dispense height (stand‑off), nozzle sweep speed, and volumetric dispense rate. Establishing robust process understanding early is therefore essential to avoid start‑up scrap, rework, and variability downstream. This paper presents a combined computational and experimental methodology to optimize and de‑risk dispensing of elastomeric battery fire protection (BFP) coatings. We develop a physics‑informed modeling
Hossain, Arif, Repollet Pedrosa, Milton H., Norquest, Kade, Mcmichael, Jonathan, Ng, Sze-Sze, Aradhyula, Pranavi, Thomas, Ryan, Gorin, Craig, Dietsche, Laura, Kenney, James A.
Impedance Characterization of an Automotive Battery Pack2026-01-0381To be published on 04/07/2026
Parasitic inductance and capacitance of the battery pack can affect the performance of the electric powertrains. Characterizing these parasitic phenomena in an automotive battery pack is therefore crucial to ensuring performance and reliability. In this work, geometric models of a production automotive battery pack are developed to simulate the parasitic inductance of the busbar system, the parasitic inductance of individual modules, and other critical components. For these simulations, several assumptions and simplifications are introduced to reduce model complexity, while preserving the main electromagnetic behavior of the system. The impact of the different components on the battery pack impedance is investigated to evaluate parasitic capacitances, thereby simulating the worst-case scenario. Laboratory procedures are developed to accurately measure parasitic impedance, providing a reliable comparison between experimental data and analytical models and supporting the overall validity
Misley, Marco, D'Arpino, Matilde, ZHU, Di, Zhang, Liwen
Guidelines for Interior Material Selection to Enhance Thermal Safety in Electric Vehicles2026-01-0249To be published on 04/07/2026
Due to the rapid advancement of electric vehicles, the role of material selection has become very critical for ensuring passenger safety, particularly in mitigating risks associated with Lithium-Ion (Li-Ion) battery thermal runaway. Unlike internal combustion engine (ICE) vehicles, electric vehicles require interior materials that provide superior fire resistance, thermal insulation, and minimal smoke emission to protect vehicle occupants in extreme thermal events. This paper examines the importance of selecting fire-resistant materials, thermally stable polymers, and low-toxicity materials that can slow fire propagation, reduce interior temperatures, and reduce hazardous gas emissions. Through the integrating of materials with high thermal stability, self-extinguishing properties, and heat-reflective coatings, manufacturers can enhance vehicle interior safety, improve passenger protection, and optimize energy efficiency.
El-Sharkawy, Alaa, Taha, Nahla, Asar, Mona, Sheta, Mai
Techno-Economic Evaluation of Electified Vehicle Options in Drayage Fleets2026-01-0454To be published on 04/07/2026
The transition of drayage fleets from diesel to battery electric vehicles (BEVs) poses both opportunities and uncertainties, especially regarding long-term economic viability. While total cost of ownership (TCO) is a useful benchmark, fleet operators and investors are equally concerned with investment performance metrics such as payback period and Internal Rate of Return (IRR), which better reflect financial risks and investment return timelines. This study proposes a comprehensive framework to evaluate the economic feasibility of transitioning from diesel to BEVs, jointly analyzing TCO parity conditions, payback periods, and IRRs under different technology, cost, and operational scenarios. Building on a previously developed cost modeling tool, the analysis incorporates evolving battery prices, energy costs, vehicle performance characteristics and other assumptions from 2025 to 2050. Real-world duty cycle data from a Class 8 drayage fleet at the Port of Savannah is used to capture
Sun, Ruixiao, Sujan, Vivek, Goulet, Nathan, Wang, Qixing
The Impact of Extreme Ambient Temperatures on Electric Vehicle Performance in the Kingdom of Saudi Arabia2026-01-0133To be published on 04/07/2026
The rapid expansion of Saudi Arabia’s electric vehicle sector driven by manufacturers such as CEER Lucid Tesla and BYD necessitates evaluating vehicle performance under extreme thermal conditions. This study investigates the impact of high ambient temperatures on electric vehicle operation by analyzing a 60 kWh NMC battery pack under representative Riyadh summer conditions of up to 47 °C using MATLAB Simulink simulations. The results show that elevated temperatures accelerate state of charge (SOC) depletion and increase battery internal resistance. To maintain safe operating limits the BTMS must operate continuously consuming up to 20 percent of the available energy. Cooling demand increases nonlinearly with temperature exceeding 40 kW at 50 °C which leads to significant parasitic losses and a 15 to 20 percent reduction in driving range. At the system level this increased energy demand raises charging frequency and intensifies electricity load during peak summer periods thereby
Bedywi, Lama Mohammed A, AlJuhani, Haneen, Duan, Chen, AbdulNour, Bashar
Accelerating Electrification Through Modular Propulsion: GM’s Strategy for BEV and BET Platforms2026-01-0410To be published on 04/07/2026
General Motors continues to advance its electrification strategy through the development of scalable Battery Electric Vehicle (BEV) and Battery Electric Truck (BET) platforms. This paper highlights GM’s latest BEV and BET products that leverage shared Drive Unit (DU), Rechargeable Energy Storage System (RESS), and integrated power electronic (IPE) components across multiple vehicle programs. By adopting a modular and commonized propulsion architecture, GM achieves significant benefits in manufacturing efficiency, cost optimization, and product flexibility. The shared DU, RESS, and IPE components are engineered to meet diverse performance requirements while maintaining high standards of energy efficiency, thermal management, and durability. This approach enables rapid deployment of electrified solutions across various segments, from passenger vehicles to full-size trucks, without compromising on capability or customer experience. The paper outlines the technical rationale behind
Liu, Jinming, Sevel, Kris, Anwar, Mohammad, Oury, Andrew, Welchko, Brian, Gagas, Brent
A Dataset for Visual Classification of Battery Fire and Smoke2026-01-0569To be published on 04/07/2026
Battery fires pose a significant risk across a wide range of applications, including electric vehicles, consumer electronics, and grid-scale energy storage systems. Early detection of fire and smoke is critical to preventing catastrophic failures and ensuring human safety. In this study, we developed a synthetic dataset of battery fire and smoke images in the context of a simple battery pack. The primary application of this dataset is to support the development of a machine learning–based visual classification system capable of accurately detecting battery fires and smoke in real time at an early stage. The intended outcome is a deployable classification system that enhances battery safety through rapid visual identification of hazardous conditions.
Govilesh, Vidarshana, Gunasekaran, Aswin, Challa, Karthikeya, Maxim, Bruce, Shen, Jie
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