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

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.