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Design of an embedded hardware platform for cell-level diagnostics in commercial battery modules

arXiv eess.SPby Gabriele Marini, Alessandro Colombo, Andrea Lanubile, William A. Paxton, Simona OnoriApril 1, 20261 min read0 views
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arXiv:2603.29107v1 Announce Type: cross Abstract: While battery aging is commonly studied at the cell-level, evaluating aging and performance within battery modules remains a critical challenge. Testing cells within fully assembled modules requires hardware solutions to access cell-level information without compromising module integrity. In this paper, we design and develop a hardware testing platform to monitor and control the internal cells of battery modules contained in the Audi e-tron battery pack. The testing is performed across all 36 modules of the pack. The platform integrates voltage sensors, balancing circuitry, and a micro-controller to enable safe, simultaneous cell screening without disassembling the modules. Using the proposed testing platform, cell voltage imbalances within

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Abstract:While battery aging is commonly studied at the cell-level, evaluating aging and performance within battery modules remains a critical challenge. Testing cells within fully assembled modules requires hardware solutions to access cell-level information without compromising module integrity. In this paper, we design and develop a hardware testing platform to monitor and control the internal cells of battery modules contained in the Audi e-tron battery pack. The testing is performed across all 36 modules of the pack. The platform integrates voltage sensors, balancing circuitry, and a micro-controller to enable safe, simultaneous cell screening without disassembling the modules. Using the proposed testing platform, cell voltage imbalances within each module are constrained to a defined reference value, and cell signals can be safely accessed, enabling accurate and non-invasive cell-level state-of-health assessments. On a broader scale, our solution allows for the quantification of internal heterogeneity within modules, providing valuable insights for both first- and second-life applications and supporting efficient battery pack maintenance and repurposing.

Subjects:

Systems and Control (eess.SY); Signal Processing (eess.SP)

Cite as: arXiv:2603.29107 [eess.SY]

(or arXiv:2603.29107v2 [eess.SY] for this version)

https://doi.org/10.48550/arXiv.2603.29107

arXiv-issued DOI via DataCite

Submission history

From: Andrea Lanubile [view email] [v1] Tue, 31 Mar 2026 00:52:52 UTC (11,295 KB) [v2] Thu, 2 Apr 2026 18:27:22 UTC (11,201 KB)

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