Researchers in Austria have developed a new battery management system (BMS) that can detect hidden damage and track aging inside electric vehicle batteries, potentially improving safety, performance, and lifespan.
The technology was developed through the EU-funded Nemo project by Graz University of Technology (TU Graz), Vrije Universiteit Brussel, and several industry partners. Unlike conventional battery management systems that mainly monitor voltage, current, and temperature, the new approach provides direct insight into conditions inside battery cells.
Current battery systems often rely on external calculations to estimate battery health. As a result, damage or aging inside individual cells can be difficult to identify until performance begins to decline.
The researchers say the new models and algorithms allow the battery management system to independently identify faults, monitor cell degradation, and determine when maintenance may be needed.
A key part of the project involved improving the system’s ability to detect safety risks before they become serious problems.
“The battery management system is an important tool for operating electric vehicles more safely and sustainably,” said Christoph Drießen from the Vehicle Safety Institute at TU Graz.
To train the system, researchers deliberately damaged battery cells in laboratory tests. Some cells were mechanically deformed to simulate incidents such as minor parking impacts. The resulting data was then used to develop algorithms capable of recognizing similar signs of damage in real-world batteries.
The system relies on electrochemical impedance spectroscopy (EIS), a sensor-based technique that measures electrical resistance inside battery cells. This allows engineers to collect information directly from within the battery rather than inferring its condition through external measurements alone.
Researchers say this additional layer of monitoring could help identify damaged cells at an earlier stage, reducing safety risks and allowing maintenance before larger problems develop.
“If we recognise faults and damage to individual battery cells at an early stage via the BMS, many dangers can be avoided,” Drießen said.
Beyond safety, the researchers also focused on understanding how batteries age over time.
The TU Graz team developed a model that predicts changes in battery cell volume during charging and discharging cycles. Excessive expansion can increase mechanical pressure inside a battery pack, raising the risk of cracks, deformation, internal short circuits, and temperature spikes.
Meanwhile, researchers at Vrije Universiteit Brussel developed models that track aging and service-life changes within individual cells.
According to the team, existing battery checks mainly reveal how much overall capacity has been lost compared to a battery’s original condition. The new approach aims to provide a more detailed picture of what is happening inside the cells as they age.
“Up to now, a test only showed how much the capacity has decreased compared to the original battery condition,” said Drießen.
“But the new models also give us an insight into the changes within the cells as they age. This enables adjustments that are beneficial for performance, service life and safety.”
Despite the added functionality, researchers say the enhanced battery management system would not significantly increase the size or weight of existing systems. A demonstrator has already been built at the battery module level, while a follow-up project will focus on advancing the technology toward industrial deployment.
The study appears in Journal of Power Source.
With over a decade-long career in journalism, Neetika Walter has worked with The Economic Times, ANI, and Hindustan Times, covering politics, business, technology, and the clean energy sector. Passionate about contemporary culture, books, poetry, and storytelling, she brings depth and insight to her writing. When she isn’t chasing stories, she’s likely lost in a book or enjoying the company of her dogs.
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