Predictive Conformal Slip Monitoring: An Empirical Evaluation of Rolling Split Conformal Prediction for Pre-Incident Traction Loss Detection

Predicting thermal volatility in high-performance EV powertrains is difficult as internal temperatures are rarely observable outside the lab, and models calibrated on lab drive cycles fail when deployed against real-world loads. We study this lab-to-track transfer problem using conformal prediction, offering distribution-free uncertainty bounds. We implement Ensemble Batch Prediction Intervals (EnbPI; Xu & Xie, 2021), a leave-one-out bootstrap-ensemble conformal method for autocorrelated time series, and calibrate it on real CALCE lithium-ion cycler data (A123 SP20 cells, FUDS profile). We evaluate it under a genuine, measured covariate shift: a second real CALCE test condition (US06 Highway Driving Schedule at 45°C). The unweighted EnbPI bound, achieving its nominal 95% coverage in-distribution (measured: 95.00%), degrades to 70.13% empirical coverage under this real shift. We introduce a weighted EnbPI procedure combining EnbPI's ensemble residuals with density-ratio weighting (Tibshirani et al., 2019), estimating the density ratio via a probabilistic domain classifier. This recovers coverage to 72.42%, a modest, honestly-reported improvement, not a complete fix. We additionally apply the calibrated model to real 2023 Formula 1 telemetry (Monza and Silverstone, driver VER) as an unsupervised out-of-distribution diagnostic. Because no internal thermal channel exists in public trackside telemetry, we report only unsupervised flag rates (65.6% at Monza, 58.0% at Silverstone, well above the 5% in-distribution base rate) and note inconsistent associations between flags and braking/DRS zones. We conclude that conformal domain adaptation is a promising but only partially solved tool for this problem, detailing exactly where it falls short.

Knowledge of real-time road slipperiness, or even better, a refined estimate of peak grip potential, is a critical input for vehicle warning and intervention control systems. Typically, friction is estimated through dynamics-based recursive estimators by calculating the slip slope; however, its efficacy is heavily constrained by the vehicle dynamic scenario. When the vehicle is cruising and there is little to no slip, these methods become ineffective due to the inability of present-day production-grade sensors, such as wheel speed sensors, and methods to either measure or accurately estimate micro slip, which is crucial for distinguishing different surfaces. To address this challenge, the correlation between vehicle signals and road surface condition during cruising needs to be uncovered using machine learning. In this paper, a feature-based framework and an end-to-end data-driven framework are used to correlate the statistics of vehicle dynamics behavior with the condition of the road surface and perform binary classification into grip, dry or damp, and slip, snow or ice, conditions. A sliding-window approach is adopted to batch a short buffered window of wheel speeds, wheel torques, longitudinal acceleration, steering angle, and yaw rate, which are fed into a machine learning module for predicting the road state. Validation results on public-road data show scenarios where the data-driven method identifies the road surface correctly even during cruising, showing promise for accurate data-driven friction-related state estimators in the field of tire and vehicle dynamics.

Conformal Prediction (CP) provides robust uncertainty guarantees for predictive models, but is typically applied post hoc, which misaligns model training with the conformal goal of producing efficient (i.e., narrow) intervals. We propose SPACR (Single-Pass Adaptive Conformal Regressor), a novel method for directly training uncertainty-aware regressors within a differentiable loss. SPACR jointly optimizes accuracy, efficiency, and validity without batch-splitting or a predefined confidence level during training. As a result, a single SPACR model yields valid prediction intervals at multiple confidence levels during inference, avoiding the costly retraining required by methods like Directly Optimized Inductive Conformal Regression (DOICR). Experiments on diverse tabular and image datasets show that SPACR consistently gives tighter intervals and better coverage-efficiency trade-offs compared to standard CP and DOICR, while significantly reducing computational costs relative to retraining-dependent baselines.