A distributed monitoring module captures thermal conditions across an EV battery pack and identifies abnormal temperature behavior for battery-management and diagnostic systems.
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Additional detail on architecture, stack and implementation specifics for this engagement.
The module distributes thermal sensing across the battery pack, feeding readings into firmware running on an automotive-grade MCU that performs real-time diagnostics and communicates pack health over the vehicle's in-vehicle bus to the broader battery-management system.
Thermal data is sampled at a rate fast enough to catch abnormal temperature gradients between cells, processed locally against fault-detection logic, and reported over the vehicle bus rather than an external network — this is an in-vehicle real-time system, not a cloud-connected consumer device.
Detecting early signs of thermal abnormality at the cell level, ahead of pack-level BMS thresholds, required tuning fault-detection logic against real thermal behavior while avoiding false triggers that would degrade trust in the system. Meeting automotive real-time and reliability expectations — deterministic timing, fault tolerance, and compliance with automotive engineering practices — shaped both the hardware and firmware design throughout.
Cell-level rather than pack-level monitoring was the point of the engagement: pack-level BMS thresholds catch problems later than a distributed sensing approach can, so the module's value depends on genuinely earlier, localized fault detection.
