Charging Phase Health Indicators for Battery State-of-Health Estimation: A Systematic Comparison of CC, CV, and Combined Approaches under Cross-Battery Validation

Reliable early detection of lithium-ion battery degradation requires health indicators that are physically interpretable and computable from routine cycler telemetry without access to the degradation region. We introduce \textsc{CausalHealth}, a framework that applies causal graph discovery and $k$-nearest-neighbour transfer entropy to per-cycle voltage, current, temperature, and resistance time series, and organises twelve resulting anomaly scores into three signal-class bundles (Magnitude-shift, Predictive-residual, Complexity-entropy) -- with Isolation Forest reported separately as it falls below the bundle reliability threshold -- to characterise detection sensitivity across ten commissioning fractions (5--30,%). The Magnitude-shift class achieves 100,% detection across all seven tested cells spanning LFP (MIT--Stanford MATR) and LCO (NASA PCoE, CALCE CS2) chemistries, with a lead time of up to 402 cycles before conventional capacity-threshold failure on gradual-fade cells. A Reliability-Weighted Master Health Index (RWMHI) -- a cross-bundle fusion of five high-reliability detectors weighted by inverse coefficient of variation -- improves lead time by 15--52 cycles over the class median on long-lived cells while maintaining 100,% detection. Validation against electrochemical impedance spectroscopy on an NMC prismatic cell provides independent physical grounding: transfer entropy $\mathrm{TE}(R \!\to\! V)$ correlates with charge-transfer resistance $R_{\mathrm{ct}}$ (pooled $r = +0.990$; temperature-controlled partial $r = +0.898$), and an Arrhenius analysis of both quantities yields an activation energy consistent with published NMC charge-transfer kinetics. These results are evaluated on seven cells across three benchmark datasets.

Supercharging of lithium-ion batteries (LiBs) requires robust health monitoring to ensure durability, safety, and user confidence, particularly for emerging vehicle-to-grid applications with bidirectional energy flows. Yet battery management remains largely disconnected from the material and structural origins of aging, limiting both interpretable health assessment and informed battery design. Here we propose a physics-informed learning framework with virtual sensing that infers hard-to-measure design parameters, including solid-state diffusion coefficient, electrode thickness, ion concentration, and particle size, directly from standard battery management system (BMS) measurements. Across diverse fast-charging strategies and driving profiles, embedding a digital-twin-derived particle-cracking mechanism as a soft constraint reduces trajectory and lifetime prediction errors by 6-8 times relative to state-of-the-art machine learning baselines using only 2% early-life observations. We further show that accurate degradation extrapolation does not require fully resolved governing equations; validated partial mechanisms, jointly refined with limited data, provide sufficient guidance. Virtual sensing transforms standard charging signals into latent design variables without additional sensors, bridging observable battery behavior and underlying aging processes while reducing capacity loss error by up to 39%, end-of-life (EOL) error by 17%, and prediction variability by up to 54%, enabling real-time exploration of new battery configurations. More broadly, the proposed framework establishes a practical feedback loop between deployment and development, demonstrating how real-world operation can continuously inform upstream design decisions across complex multiphysics systems.

Early battery degradation trajectory forecasting (BDTF), which predicts the full-life state-of-health trajectory from early operational data, is critical for battery optimization, manufacturing, and deployment. Battery degradation data exhibit two key characteristics. First, degradation data present a multi-level structure, including regularities shared within aging conditions and trajectory patterns shared across batteries. Second, degradation-related variations in voltage-current profiles are often localized to specific state of charge (SOC) intervals. Existing approaches often fail to explicitly model these characteristics. To bridge this gap, we propose BatteryMFormer, a multi-level Transformer for early BDTF. BatteryMFormer integrates (1) an aging-condition-aware decoder that injects aging-condition priors via aging-condition-informed queries and aging-condition-aware attention, (2) a meta degradation pattern memory that learns and retrieves trajectory prototypes to guide long-horizon forecasting, and (3) a dual-view encoder that jointly captures temporal dynamics and SOC-localized variations from voltage and current time series. Extensive experiments on four battery domains show that BatteryMFormer consistently outperforms state-of-the-art baselines, marking a significant step toward reliable BDTF. Our code is available at https://github.com/Ruifeng-Tan/BatteryMFormer.