Infrared Hotspot-Guided Early Warning of Lithium-Ion Battery Thermal Runaway Under Mechanical Abuse

Abstract:Mechanical abuse can trigger thermal runaway (TR) in lithium-ion batteries through localized heat generation before sensor signals become decisive. This paper proposes a two-stage early-warning approach that estimates localized thermal instability from infrared hotspot dynamics and then fuses this instability score with mechanical, electrical, thermal, and image-intensity features for a 20-frame warning horizon. Evaluation uses repeated experiment-wise three-fold validation, with out-of-fold Stage-I scores during Stage-II training to prevent stacked-model optimism. Hotspot dynamics alone achieve Stage-I ROC-AUC 0.945, and the two-stage classifier reaches Stage-II ROC-AUC 0.908, exceeding direct multimodal fusion while preserving an interpretable intermediate instability signal. Thermal gradient rise precedes voltage-based detection by 40 frames (4 seconds) on average, enabling earlier battery management system intervention. Lead-time analysis at a fixed 0.5 threshold yields a 14.8-frame mean lead time.

Systems and Control (eess.SY); Artificial Intelligence (cs.AI)

arXiv:2608.20383 [eess.SY]

(or arXiv:2608.20383v1 [eess.SY] for this version)

https://doi.org/10.48550/arXiv.2608.20383 Focus to learn more arXiv-issued DOI via DataCite

arXivLabs is a framework that allows collaborators to develop and share new arXiv features directly on our website.

Both individuals and organizations that work with arXivLabs have embraced and accepted our values of openness, community, excellence, and user data privacy. arXiv is committed to these values and only works with partners that adhere to them.

Have an idea for a project that will add value for arXiv's community? Learn more about arXivLabs.