Modern EV battery packs contain thousands of cells operating at voltages up to 800V and currents exceeding 500A, with individual cell monitoring requirements down to millivolt precision. These systems must maintain measurement accuracy across temperature ranges from -40°C to 85°C while detecting subtle voltage signatures that can indicate imminent thermal events.

The fundamental challenge lies in achieving precise, high-speed monitoring of numerous cells while maintaining signal integrity across harsh automotive environments and electromagnetic interference.

This page brings together solutions from recent research—including temperature-regulated current shunts, voltage rebound detection systems, ranking-based cell imbalance monitoring, and wavelet-based thermal event prediction. These and other approaches focus on early detection of potential failures while maintaining measurement accuracy during normal operation.

1. Sensors Innovations for Smart Lithium-Based Batteries: Advancements, Opportunities, and Potential Challenges

jamile mohammadi moradian, amjad ali, xuehua yan - Springer Science+Business Media, 2025

Abstract Lithium-based batteries (LiBs) are integral components in operating electric vehicles to renewable energy systems and portable electronic devices, thanks their unparalleled density, minimal self-discharge rates, favorable cycle life. However, the inherent safety risks performance degradation of LiB over time impose continuous monitoring facilitated by sophisticated battery management (BMS). This review comprehensively analyzes current state sensor technologies for smart LiBs, focusing on advancements, opportunities, potential challenges. Sensors classified into two primary groups based application: optimization. Safety sensors, including temperature, pressure, strain, gas, acoustic, magnetic focus detecting conditions that could lead hazardous situations. Performance optimization such as optical-based electrochemical-based, monitor factors charge health, emphasizing operational efficiency lifespan. The also highlights importance integrating these sensors with advanced algorithms control approaches optimize charging discharge cycles. Potential advancements driven nanotechnolo... Read More

2. Intelligent Battery Management in a Hybrid Photovoltaic Using Fuzzy Logic System

joann v magsumbol, argel a bandala, alvin b culaba - Multidisciplinary Digital Publishing Institute, 2025

LiFePO4 batteries need a battery management system (BMS) to improve performance, extend their lifespan, and maintain safety by utilizing advanced monitoring, control, optimization techniques. This paper presents the design, development, implementation of an intelligent (i-BMS) that integrates real-time monitoring control batteries. The was extensively tested using multiple datasets, results show able temperature within set range, balance cell voltages, distribute energy according load prioritization. It uses fuzzy logic approach effectively manage farm requirements. Additionally, proposed method embedded three-level prioritization algorithm woven into rule allocate dynamically among essential, regular, non-essential loads.

3. IoT-Based BMS for Remote Battery Health Monitoring and Optimization

g shasikala, n nayana, n thameem, 2025

This project presents the development of an IoT-based Battery Management System (BMS) utilizing Random Forest Regressor machine learning model for remote battery health monitoring and optimization. The system integrates IoT-enabled sensors to collect real-time parameters such as voltage, current, temperature. data is transmitted through secure IoT gateways a cloud platform processing. employed predict critical metrics, including capacity degradation remaining useful life. enhances predictive accuracy enables informed decision-making optimized usage, thereby improving efficiency longevity. innovative solution demonstrates potential combining revolutionize management foster sustainable energy solutions.

4. Multiband Multisine Excitation Signal for Online Impedance Spectroscopy of Battery Cells

roberta ramilli, nicola lowenthal, marco crescentini - Multidisciplinary Digital Publishing Institute, 2025

Multisine electrochemical impedance spectroscopy (EIS) represents a highly promising technique for the online characterization of battery functional states, offering potential to monitor, in real-time, key degradation phenomena such as aging, internal resistance variation, and state health (SoH) evolution. However, its widespread adoption embedded systems is currently limited by need balance measurement accuracy with strict energy constraints requirement short acquisition times. This work proposes novel broadband EIS approach based on multiband multisine excitation strategy which signal spectrum divided into multiple sub-bands that are sequentially explored. enables available be concentrated portion at time, thereby significantly improving signal-to-noise ratio (SNR) without substantially increasing total time. The result more energy-efficient method maintains high diagnostic precision. We further investigated optimal design these sequences, taking account realistic imposed sensing hardware limitations amplitude noise level. effectiveness proposed was demonstrated within comprehensiv... Read More

5. Battery Management System with Busbar Voltage Offset Correction and Dual-Module Data Acquisition

AMPERE SAS, NISSAN MOTOR CO LTD, 2025

Battery management system for electric vehicles with a refined voltage measurement technique to optimize battery performance and durability. The system manages an electric battery device with multiple modules connected in series, each containing cells. Some cells are connected by a busbar. The measurement technique accounts for busbar voltage offsets. It uses a single slave element to gather data from two modules. Measurements from cells on the busbar are adjusted based on the busbar resistance. This prevents overestimation due to busbar voltage. The adjusted cell voltages are used for safety methods like derating charging power. The technique improves accuracy by avoiding erroneous voltage readings from busbar cells.

6. Method for Estimating Initial Battery State of Charge Using Voltage-Current Polarization Adjustment

AMPERE SAS, NISSAN MOTOR CO LTD, 2025

Method for accurately estimating the initial state of charge of a battery in a hybrid or electric vehicle, particularly when the battery has not been at rest for a long time. The method involves estimating an initial value of the state of charge during an initialization phase. The initialization phase includes steps like measuring the battery's voltage and current at the start of charging or discharging, calculating the current polarization based on the voltage and current values, and using the polarization to adjust the initial state of charge estimate. This takes into account the battery's polarization state to provide a more accurate initial state of charge estimate when the battery has not been resting for a long time.

7. High Voltage Battery Protective Circuit with Heat Generator Fuses and Auxiliary Power Control

DEXERIALS CORP, 2025

Protective circuit for high voltage, high current secondary battery applications like electric vehicle batteries. The circuit has a protective element with fuses, a heat generator, and terminals connected to the battery and auxiliary power. When an abnormality is detected, a control device switches an auxiliary power supply to energize the heat generator fuses, cutting off the battery from the external terminals. The heat generator fuses prevent excessive currents and voltages from damaging the battery. The auxiliary power allows high voltage fuses without voltage rating issues. The control device can detect abnormalities like overvoltage or overcurrent.

8. Battery Cell Voltage Detection Using Converters and Switching Units with Current Routing Mechanism

O2MICRO INC, 2025

Method and controller for accurately detecting voltages of battery cells in a battery pack using converters and switching units. The method involves routing the operating current from the battery cell anode through the converter to ground, while also routing a sampling current from the battery cell anode to the converter. This reduces the difference between currents through the anode and cathode paths, allowing the converters to accurately detect the cell voltage.

9. Electric Vehicle Battery Charging Estimation by ANN and Fuzzy Logic

sagar subhash chikurdekar - Lectito Journals, 2025

The state of charge (STOC) lithium-ion batteries (LTIB) poses a significant challenge in the implementation and advancement battery management systems, necessitating precise measurement capacity utilized electric vehicle (EV) development, thereby emerging as straightforward issue. Efficient regulation energy, to mitigate dangers associated with overcharging over-discharging, is feasible only an accurate calculation STOCH, which supports several situations constraints. In STOCH esteem analysis, it imperative account for influence diverse components on operational cycle batteries, such cell aging imbalance, by employing various sophisticated similar circuit models batteries. Fitting assessment computations are employed quantify improve precision evaluations. systems (BMTS) essential vehicles (EVs). admiration, denoting excess limit or also constitutes central border BMTS. This approach use perpetual control value via Arduino UNO microcontroller. Additionally, we will examine display using simulation associate degree regulator utilizing MATLAB Simulink model. MATLAB, ANN model be develo... Read More

10. Enhancing Fire Protection for Electric Vehicle Batteries

kranti saran - Indospace Publications, 2025

Abstract - Electric vehicle battery packs need a complex Battery Management System (BMS) for vital parameter monitoring such as voltage, current and state of charge temperature to ensure safety together with operational efficiency. This research explores the BMS mechanisms which include external aging notifications through smoke detection followed by alarm sounds an optimal cooling system along automatic charging prevent degradation. Short-circuit protection devices in batteries decrease electrical failure risks can both fires dead batteries. The provides continuous power delivery real-time fast maintenance procedures under any possible condition. Key Words System(BMS), Vehicle Battery, Fire Protection, Thermal Management, Smoke Sensor, Short Circuit Real-time Monitoring, Safety, SOC.

11. QR Based EV Bulk with Overcharge Protection and Prevention

antony robinson j, m athvani, mohammed irfan f - International Journal for Multidisciplinary Research (IJFMR), 2025

The increasing adoption of Electric Vehicles (EVs) has highlighted the need for efficient and safe charging systems. One major challenges in EV infrastructure is preventing overcharging, which leads to battery degradation, reduced lifespan, potential safety hazards. Therefore, this paper presents a Quick Response (QR)-based bulk system integrated with overcharge protection prevention mechanisms. A solar panel, an ATmega 328 microcontroller, Node MCU, battery, Liquid Crystal Display (LCD), IoT device are some components work. proposed utilizes QR code technology easy identification access control stations, enabling seamless user interaction. data gathered by sent users using IoT, it monitored BLYNK app. uploaded app cloud database via MCU module embedded inside microcontroller. It also integrates advanced based algorithms real-time monitoring protect against ensuring that EV's charged efficiently, safely, within its optimal capacity. This prevents incorporates smart algorithm monitors battery's state real-time.

12. Method for Identifying Voltage Abnormalities in Batteries Using Temporal Variations in Measured and Estimated Open Circuit Voltage Discrepancies

LG ENERGY SOLUTION LTD, 2025

Diagnosing abnormalities in voltage behavior of batteries based on changes in differences between measured open circuit voltage data and estimated open circuit voltage data over time. The method involves generating open circuit voltage (OCV) data from the battery, deriving estimated OCV data based on the measured data, and diagnosing battery health based on the difference between the measured and estimated OCV values. This allows detecting subtle voltage abnormalities even when the battery voltage itself doesn't change significantly.

US2025123334A1-patent-drawing

13. Battery Charging System with Anode Potential-Based Current Regulation to Prevent Lithium Plating

KIA CORP, 2025

Controlling battery charging to prevent lithium plating on anode surfaces through a novel voltage-based charging strategy. The approach measures the potential difference between reference and anode terminals in each cell and determines the charging current based on the minimum anode potential. This approach prevents lithium deposition by directly controlling the charging current based on the anode potential, eliminating the need for traditional lithium deposition rate measurement. The strategy ensures optimal charging conditions for each cell while preventing excessive lithium deposition.

14. Electric Vehicle Discharge Circuit Diagnostic System with Series-Connected Sensor

FORD GLOBAL TECHNOLOGIES LLC, 2025

A diagnostic system for discharge circuits in electric vehicles that can detect if the discharge circuit is functioning properly. The system includes a sensor connected in series with the discharge circuit. During a diagnostic check, the control system operates the discharge circuit to dissipate charge. If the sensor detects no change in electrical characteristic, it indicates the discharge circuit is deficient and provides a notification. This allows proactive detection of faulty discharge circuits to prevent issues like incomplete charge dissipation during vehicle shutdown.

US2025121690A1-patent-drawing

15. Discharge Device with Controlled Transition Strategy and Sensor-Based Real-Time Adjustment for Secondary Batteries

SK ON CO LTD, 2025

Discharge device for secondary batteries that optimizes charging and discharging while maintaining battery health. The device employs a controlled discharge strategy that transitions from primary discharge to secondary discharge at specific voltage and current rates. This approach maintains the battery's state of charge while preventing excessive stress on the cells. The device includes sensors to monitor battery voltage, current, and temperature, enabling real-time adjustments to the discharge parameters. The controlled discharge strategy ensures safe and efficient battery management, particularly for batteries nearing the end of their lifespan.

16. Battery Cell Damage Prediction System Utilizing Voltage and Temperature Monitoring with Accumulative Weighting Factor Analysis

SAMSUNG SDI CO LTD, 2025

Predicting damage to battery cells by monitoring voltage and temperature within a damage range and calculating a weighting factor based on the readings. If the cell's voltage or temperature falls within the damage range, the cell is disconnected to prevent further damage. The weighting factor is accumulated over time to determine the overall damage level. If the accumulated weighting exceeds a threshold, the cell is permanently blocked. This allows managing cells based on damage history and replacing them at appropriate intervals.

US2025125430A1-patent-drawing

17. Wireless Battery Monitoring System with Synchronized Voltage and Current Data Acquisition for Electric Vehicles

DENSO TEN LTD, DENSO CORP, 2025

Battery monitoring system for electric vehicles that allows synchronized acquisition of battery voltage and current data without wired connections. The system uses wireless communication between a central monitoring device and individual battery measurement devices. The monitoring device sends voltage measurement commands to the battery devices at regular intervals. The battery devices measure voltage at those times. The monitoring device then synchronously acquires current data from onboard sensors during the same time intervals to match the voltage measurements. This allows calculating battery resistance without requiring precise timing coordination.

US2025123336A1-patent-drawing

18. Battery Pack with Balancing Switches and Current Sensor for Reverse Voltage Limitation

SAMSUNG SDI CO LTD, 2025

Battery pack design and protection method to prevent reverse voltage damage when a cell fuse blows in a battery pack. The pack has balancing resistors, switches, and a current sensor between the pack terminals. If a cell fuse blows, the controller detects the increased pack current and turns on all the balancing switches to form a closed circuit through the resistors. This limits reverse voltage across the blown fuse to protect the cell. If a short is detected, it turns on all balancing switches. After a short, it checks for fuse blowout.

US2025125637A1-patent-drawing

19. Battery Management System with Optical Communication via Reflective Film Interfaces

VITESCO TECHNOLOGIES USA LLC, 2025

Battery management system (BMS) using optical communication between batteries instead of wires to address issues like cyber-attacks, EMI, bulky wiring, and slow data transfer. The BMS has optical devices connected to each battery that emit and receive optical signals containing battery data through transparent and reflective films. The signals bounce between films to transfer between batteries. This allows fast, immune, and secure battery monitoring without wires.

20. Electronic Current Control System with Integrated Current Monitor for Autonomous Vehicle Pulsed Electronics

GM CRUISE HOLDINGS LLC, 2025

An electronic current control system for autonomous vehicles that automatically limits electrical current to pulsed or switching electronics like motors and LIDAR sensors without latency or user intervention. The system adds a current monitor component to the electrical pathway between the power supply, current control component, and pulsed/switching electronics. The monitor adjusts the current control component based on a threshold voltage compared to the output voltage, without needing the main processor. This provides faster, localized current limiting to prevent unsafe thermal events in the pulsed electronics.

21. Battery Diagnosis System Utilizing Voltage Deviation and Rate of Change Analysis for Low Voltage Cell Identification

22. Simulation Based Battery Management System

23. Multi-Module Battery Pack with Impedance-Based Voltage Compensation Mechanism

24. Power Storage Pack with Contact Resistance Measurement and Authentication Controller

25. Battery Short Circuit Differentiation and Response System with Parameter Monitoring and Profile Comparison

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