Data-Driven PHM with BDPS Tool Suite: Battery Data Acquisition for Degradation Modeling

The Battery Diagnostics and Prognostics System (BDPS) Tool Suite advances Prognostics and Health Management (PHM) through its innovative Data Acquisition (DA) Toolbox, the backbone for robust data collection, degradation modeling, and lifecycle prediction. Operating at 1 Hz with 0.05% voltage accuracy and ±5 mA current precision, the DA Toolbox integrates with battery cyclers to collect real-time voltage, current, capacity, and temperature data across -30°C to 60°C and varying Crates for NMC, LFP, and NCA chemistries. This data drives hybrid models blending empirical trends with electrochemical simulations to reveal degradation mechanisms like capacity fade, temperature spikes, SEI growth, lithium plating, loss of active material (LAM), and loss of lithium inventory (LLI). Using the Adaptive Remaining Useful Life Estimator (ARULE), BDPS delivers 95% accurate SoH and RUL predictions over 500+ lithium-ion cycles. The DA Toolbox’s affordability, modularity, and secure CSV/JSON data management with cloud synchronization enhance accessibility and scalability for startups, labs, and industry, providing actionable insights for maintenance and resilience in applications like electric vehicles (EVs) and grid-energy storage.