Causal Anomaly Detection for Lithium-Ion Battery Degradation

Accurate assessment of lithium-ion battery ageing is challenged by cell-to-cell variability, heterogeneous cycling protocols, and limited transferability of data-driven models across datasets. In particular, robust identification of degradation transitions, such as the knee point, and reliable early-life prediction of remaining useful life (RUL) remain open problems. This study proposes a unified framework for battery ageing analysis based on continuous representations of voltage-capacity and capacity-cycle trajectories learned from heterogeneous public datasets (NASA, CALCE, ISU-ILCC). The continuous formulation enables consistent extraction of degradation descriptors, including curvature, plateau length and knee-related metrics, while reducing sensitivity to dataset-specific discretisation. Across more than 250 cells, statistically significant correlations between knee onset and end-of-life (Pearson 0.75-0.84) are observed. Additional early-life analysis confirms that knee-related features retain predictive value when estimated from partial trajectories. Early-life models provide increasingly stable RUL predictions as the number of observed cycles increases, with meaningful predictive performance emerging within the first 5-20 cycles and remain robust under cross-dataset domain shift. The framework integrates continuous modelling, feature extraction and uncertainty-aware prediction, providing an interpretable and dataset-consistent approach demonstrating robustness across heterogeneous dataset types. Compared with conventional discrete or feature-based methods, the proposed representation reduces sensitivity to sampling resolution and improves cross-dataset consistency. The study is limited to laboratory-scale datasets and capacity-based end-of-life definitions.

Thermal runaway in lithium-ion batteries poses a major safety risk to electric vehicles and energy storage systems. Current early-warning methods depend mainly on temperature and may therefore miss mechanical precursors that emerge before rapid heating. We introduce a regime-aware, physics-guided framework that integrates temperature, voltage, force, deformation, and state-of-charge measurements for early warning under controlled mechanical abuse. A lightweight convolutional classifier first infers safe, warning, or danger regimes from mechanical signals. These regime estimates then condition a causal temporal convolutional backbone through feature-wise linear modulation, physics-biased attention, and regime-dependent gating. Joint learning unifies regime identification, thermal-runaway detection, and time-to-disaster estimation. We evaluate the framework using leave-one-experiment-out cross-validation on 30 mechanical-abuse tests across state-of-charge levels of 10%, 50%, and 90% and two loading protocols. The method achieves an F1 score of 0.89, a high-temperature prediction root-mean-square error of 12.3 °C, a mean warning lead time of 15.6 s, a detection success rate of 0.92, and an experiment-level false alarm rate of 2.7%. Its lead time exceeds that of the strongest baseline by 69.6%. Removing force reduces the lead time by 60.3%, highlighting the value of mechanical precursors. These results support regime-aware thermo-mechanical fusion as a promising strategy for earlier and more reliable thermal-runaway warning under controlled abuse conditions.

Multimodal industrial anomaly detection has largely focused on discrete products using strongly correlated RGB and 3D observations, leaving continuous process manufacturing and weakly correlated sensing modalities underexplored. We introduce LIBAD, the first multimodal anomaly detection benchmark for Li-ion battery electrode manufacturing. Collected from real roll-to-roll production lines, LIBAD provides aligned double-sided visible-light imaging, high-resolution X-ray radiography, and inline-compatible low-resolution X-ray radiography. Electrode patches in LIBAD exhibit highly homogeneous material appearance, while defect evidence can be strong in one modality but weak or absent in another, resulting in pronounced cross-modal anomaly inconsistency. Benchmarks of representative methods under the inline-compatible visible-light and low-resolution X-ray setting exhibit limited transferability and consistently high false-positive rates. We therefore propose DA-Core, a memory-based method that jointly considers feature-space coverage and local density of normal features during coreset selection, allowing compact memory banks to better preserve fine-grained normal variations. With a coreset ratio of 0.05, DA-Core reduces FPR95 from 60.4% to 54.3% compared with standard farthest point sampling. At this ratio, DA-Core also outperforms the best standard coreset result (obtained at 0.20) while reducing inference time by 43.9%. These results suggest that both the data distribution of normal features and the modality relationship itself require explicit consideration when designing anomaly detection methods for process manufacturing.