In the shift toward electrification and energy-efficient systems, the ability to accurately monitor and manage batteries is a key challenge for improving safety, efficiency, and reliability. As part of the OPEVA European project, demo 3 – improved sensors for accurate battery monitoring is developing next-generation sensing and management technologies that enhance battery intelligence and predictive maintenance capabilities.
Through the integration of multi-sensor monitoring, wireless data acquisition, and cybersecurity-enhanced communication, demo 3 is paving the way for smarter, more efficient, and more resilient battery systems, applicable to electric vehicles, industrial applications, and energy storage solutions.
Subtitle: new approaches to battery monitoring
Traditional battery management systems rely mainly on voltage and temperature measurements, which, while useful, provide only a limited picture of a battery’s overall state of health. Demo 3 takes a more advanced approach, integrating a variety of sensors to capture deeper insights into battery performance and degradation.
By combining electrochemical impedance spectroscopy (EIS), strain sensors, and wireless temperature sensing, the project aims to improve how we assess state-of-health and predict failures before they happen. This approach enhances real-time monitoring, making it possible to detect issues at an early stage and optimize energy use over the battery’s lifetime.
A key advantage of this approach is the reduction of cabling complexity. Wireless sensors make installation and maintenance easier, while still providing precise, real-time data. These improvements set the stage for batteries that are not only more efficient but also more reliable and adaptable to future energy storage needs.
Subtitle: integration of sensing technologies with battery management systems
Beyond developing better sensors, demo 3 is also working to ensure that all data collected can be effectively processed and used for intelligent battery management. The project integrates sensing technologies directly into the battery management system (BMS), creating a more responsive and adaptable control system.
This integration enables direct and secure communication between sensors and the BMS, allowing real-time adjustments based on operational conditions. By harmonizing different sensing methodologies, demo 3 creates a cohesive monitoring framework that enhances battery performance, stability, and predictive maintenance.
Additionally, efforts are being made to ensure secure data transmission across the system. Protecting communication between sensors, the BMS, and external diagnostic platforms is essential to maintainingsystem integrity and preventing unauthorized access.
Subtitle: cybersecurity and data protection for battery monitoring systems
As battery systems become more connected, cybersecurity is playing an increasingly important role. Demo 3 incorporates advanced security measures to protect sensor communication, BMS data exchange, and remote diagnostics.
To safeguard the system, a threat analysis and risk assessment (TARA) methodology is being applied to identify vulnerabilities and develop mitigation strategies.
By aligning with EU regulatory standards, including the Battery Passport initiative, demo 3 ensures that its security framework is not only robust but also compliant with emerging industry requirements.
Subtitle: from laboratory testing to real-world validation
The technologies developed in demo 3 will soon move toward real-world testing. This final phase will focus on assessing system performance in operational conditions to verify that the sensors, BMS integration, and cybersecurity measures will function as intended.
The validation process will include integration into a demonstrator vehicle, where real-time battery monitoring will be tested under practical conditions.
Through this testing, demo 3 will refine its models and ensure that the developed technologies can be effectively applied in real applications, supporting the broader goal of smarter, safer, and more sustainable energy storage.
Subtitle: conclusion – enabling the next generation of intelligent battery systems
By combining multi-sensor monitoring, predictive analytics, and cybersecurity, demo 3 is setting the stage for a new generation of intelligent battery systems. These advancements will enhance energy storage reliability, extend battery lifespan, and improve the efficiency of electrification across multiple industries.
With testing and validation now in progress, demo 3 is approaching a key milestone in the development of fully integrated, secure, and intelligent battery management solutions. As the project continues, it will play an essential role in shaping the future of sustainable mobility and industrial energy applications.