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

Joint remaining useful life (RUL) prediction and capacity estimation require representations of both gradual degradation and recent battery behavior. This paper presents a cross-expert framework using partial-charging measurements without requiring measured historical full-cycle capacity as an input. The RUL Expert captures long-term degradation from nominal 10-min segments sampled across a 30-cycle history, while the Capacity Expert characterizes recent battery behavior from statistical descriptors of nominal 40-min segments over ten consecutive cycles. Their complementary representations are integrated through feature-wise linear modulation for joint RUL and capacity prediction. A key contribution is a three-stage training strategy that progressively controls frozen and trainable components: supervised representation pretraining, independent expert pretraining, and final fusion training with both experts frozen. This staged optimization preserves expert-specific degradation knowledge while improving the balance between the two prediction tasks, with RUL treated as the primary prognostic objective. On two public battery-aging datasets, the reference configuration achieves mean RUL root-mean-square errors of 143.69 and 161.10 cycles and capacity errors of 12.36 and 7.28 mAh, respectively. On Dataset I, cross-expert fusion reduces both mean errors relative to either standalone expert. The proposed framework achieves the lowest reported RUL RMSE among the compared methods on both datasets while maintaining competitive capacity-estimation accuracy.

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.