PiDDM: Physics-Informed Differentiable Degradation Modeling for Lithium-Ion Battery State-of-Health Prediction

Long-horizon physics-based simulations of battery degradation provide mechanistic insight but remain computationally expensive, limiting their use for dense exploration of operating conditions over extended cycle life. Here, we propose a hybrid physics-probabilistic learning framework for surrogate modeling of lithium-ion battery degradation trajectories at unseen charging rates. Cycle-resolved degradation data generated with a DFN/P2D electrochemical model in PyBaMM are first transformed into capacity-aligned voltage and derivative features and encoded using a Variational Autoencoder (VAE). The resulting two-dimensional latent space organizes degradation trajectories according to both cycle progression and charging protocol. A sparse multitask Gaussian process (GP) is then trained in this latent space using cycle number and C-rate as input variables, providing continuous interpolation of latent degradation dynamics together with posterior uncertainty estimates. Under protocol-level holdout evaluation, the latent-space GP accurately recovers unseen C-rate trajectories and exhibits uncertainty behavior consistent with the support of the training data. When queried at unseen interior C-rates, the model generates latent trajectories that remain coherently positioned between neighboring simulated protocols. Decoding the GP-predicted latent states through the frozen VAE decoder yields smooth voltage-capacity evolution, while Monte Carlo propagation of the GP latent posterior through an auxiliary latent to State of Health (SOH) predictor provides uncertainty-aware SOH estimates. The proposed BattVAE-GP framework therefore offers a computationally efficient and uncertainty-aware surrogate for long-horizon degradation modeling, providing a structured basis for extending battery health prediction toward richer operating conditions and future simulation-experiment fusion.

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.

Accurate prediction of thermal runaway in lithium-ion batteries is essential for ensuring the safety, efficiency, and reliability of modern energy storage systems. Conventional data-driven approaches, such as Long Short-Term Memory (LSTM) networks, can capture complex temporal dependencies but often violate thermodynamic principles, resulting in physically inconsistent predictions. Conversely, physics-based thermal models provide interpretability but are computationally expensive and difficult to parameterize for real-time applications. To bridge this gap, this study proposes a Physics-Informed Long Short-Term Memory (PI-LSTM) framework that integrates governing heat transfer equations directly into the deep learning architecture through a physics-based regularization term in the loss function. The model leverages multi-feature input sequences, including state of charge, voltage, current, mechanical stress, and surface temperature, to forecast battery temperature evolution while enforcing thermal diffusion constraints. Extensive experiments conducted on thirteen lithium-ion battery datasets demonstrate that the proposed PI-LSTM achieves an 81.9% reduction in root mean square error (RMSE) and an 81.3% reduction in mean absolute error (MAE) compared to the standard LSTM baseline, while also outperforming CNN-LSTM and multilayer perceptron (MLP) models by wide margins. The inclusion of physical constraints enhances the model's generalization across diverse operating conditions and eliminates non-physical temperature oscillations. These results confirm that physics-informed deep learning offers a viable pathway toward interpretable, accurate, and real-time thermal management in next-generation battery systems.