from chemistry to pack
Current Sensor Drift and SOC Estimation Error Propagation This is a worked example accompanying Failure Mode and Effects Analysis (FMEA) in Battery Design. It is the System FMEA example in the set, and deliberately chosen because it shows something the cell-level and pack-level examples cannot: a failure that originates in one subsystem (a sensor) and … Read more
Busbar Joint Failure Modes and Contact Resistance This is a worked example accompanying Failure Mode and Effects Analysis (FMEA) in Battery Design. It works through a pack-level DFMEA line on a bolted busbar joint, a component that is mechanically simple but disproportionately responsible for field failures because it sits at the intersection of high current, … Read more
Separator Failure Modes and Internal Short Circuit This is a worked example accompanying Failure Mode and Effects Analysis (FMEA) in Battery Design. It walks through a single DFMEA line at cell level in full, from failure mode to recommended action, using the separator as the subject. The separator is a good first example because it … Read more
Why Certification Alone Won’t Save Us Introduction Lithium-ion batteries power modern life, from the phone in your pocket to the electric vehicle in your driveway to the grid-scale energy storage facility humming at the edge of town. With this ubiquity comes an uncomfortable truth: these systems store enormous energy in compact volumes, and when they … Read more
Virtual temperature sensors (also referred to as “soft sensors” or “sensorless estimators”) are software-based algorithms that estimate the temperature of battery cells without relying on a direct, physical hardware sensor at the measurement location [2]. Instead of measuring heat directly, these virtual sensors act as real-time state reconstruction algorithms running within the Battery Management System … Read more
The exact number of temperature sensors you need depends on the size of your battery pack, its physical configuration, rate of charge/discharge (C-rate), and the required level of thermal observability. In commercial Battery Management Systems (BMS), it is common practice to use one temperature sensor for every 4 to 20 cells, depending on the specific … Read more
When a lithium-ion battery cell experiences thermal runaway (due to mechanical intrusion, defects, or electrical abuse), it releases a superheated, highly pressurized gas plume containing vaporized electrolyte and carbon particles. This gas behaves as an electrically conductive fluid. In conventional battery packs, if this gas vents randomly into the pack cavity, the blasting hot airflow … Read more
Review based on Arthur Claire’s LinkedIn post. Many people think that BESS fires are always due to the batteries 🔋 🔥 This is not what the data are saying. Chinese researchers just published the most complete root-cause breakdown of global BESS fires from 2016 to 2025 with 102 incidents analysed. The root cause split is … Read more
Author: Donal Finegan The answer is not as obvious as it might seem. Work led by Siddhartha Nanda and Hadi Khani published in Royal Society of Chemistry journal of Energy and Environmental Science, dives into the sources of heat generation for Triethyl Phosphate (TEP) with KFSI electrolyte and a potassiated graphite anode: Potassium (K)-ion batteries … Read more
Author: Dominic Pascal Förstermann, Akkuracy Battery chemistry choices affect everything from product safety certifications to insurance and procurement decisions — yet the common viewpoint remains “LFP is safe, NMC is dangerous.” But is that actually true? This article looks at the empirical data. In order to describe the safety aspects fully, it is split into … Read more