Europe is leading the charge when it comes to sustainability and circularity. With the introduction of Regulation (EU) 2023/1542, batteries are taking centre stage in this shift with Electric vehicles, light means of transport, and large-scale energy storage. With the mass adoption of batteries, battery safety is becoming one of the biggest concerns. Among all the risks, thermal runaway poses the biggest threat.
Thermal runaway is a chain reaction inside a battery cell that can lead to rapid temperature increase, leading to fire incidents as well as, in extreme cases, explosions.
As battery systems become increasingly complex, the industry is moving towards data-driven safety approaches. One of the most promising developments is the integration of the Battery Management System (BMS) with the Digital Battery Passport (DBP). With the help of connecting live operational data with structured lifecycle records, stakeholders can move closer to early hazard detection and more effective risk management.
What is Thermal Runaway & What are its Risks?
Thermal runaway occurs when a battery cell experiences an uncontrollable increase in temperature due to internal failures, overcharging, external heating or physical damage. Once initiated, this chain reaction can affect the neighbouring cells, leading to system-level failure.
According to the U.S. Department of Energy, thermal runaway can be triggered by factors such as internal short circuits, overcharging and exposure to high temperatures. These events can result in the release of flammable gases and rapid heat escalation.
As electric vehicles and energy storage systems scale, the potential impact of such incidents increases. Early detection and intervention are therefore essential.
The Role of Battery Management Systems in Safety
Battery Management Systems are designed to monitor and control battery operation in real time. A BMS typically tracks parameters such as:
- Cell voltage and current
- Temperature across modules
- State of charge and state of health
- Charging and discharging behaviour
When abnormal conditions are detected, the BMS generates alerts or triggers protective actions, such as limiting current or disconnecting the battery.
Research from the National Renewable Energy Laboratory highlights that advanced BMS architectures can detect early warning signs of thermal instability by analysing deviations in temperature and voltage behaviour.
However, these alerts are often confined to internal systems. Their value is not always fully realised across the broader battery lifecycle.
How Linking BMS Alerts to The Digital Battery Passport Can Help
The Digital Battery Passport, required under Regulation (EU) 2023/1542, introduces a structured, interoperable digital record for batteries placed on the EU market. It includes data on performance, safety, composition and lifecycle events.
Linking BMS-generated alerts to the DBP extends the usefulness of safety data beyond the immediate operational context. Instead of remaining within a closed system, critical warning signals can become part of a shared, traceable safety record.
This integration enables several important capabilities.
Early Hazard Visibility Across Stakeholders
When BMS alerts are recorded within or linked to the passport, authorised stakeholders such as manufacturers, service providers and regulators can access early warning signals. This improves situational awareness and allows faster response to emerging risks.
Improved Risk Assessment Over Time
Aggregated alert data helps identify patterns that may indicate design weaknesses, operational risks or environmental stress factors. Over time, this can support predictive models for thermal runaway and improve system design.
Enhanced Safety During Second Life And Recycling
Batteries entering second-life applications or recycling facilities carry residual risks. Access to historical alert data allows operators to assess whether a battery has experienced abnormal conditions, improving handling procedures and reducing safety incidents.
From Real-Time Monitoring to Predictive Safety
The next step in battery safety is moving from reactive alerts to predictive risk assessment. By combining real-time BMS data with historical lifecycle information stored in the DBP, advanced analytics can identify early indicators of failure.
For example, gradual increases in internal resistance, repeated high-temperature events or irregular charge patterns may signal degradation pathways that precede thermal runaway. When these signals are captured and analysed across many batteries, predictive models become more accurate.
The International Energy Agency has highlighted the importance of digitalisation and data in improving battery performance and safety across the lifecycle.
Integrating BMS alerts with passport data supports this shift towards data-driven safety management.
Technical Considerations for BMS Integration
Linking BMS alerts to the Digital Battery Passport requires careful system design. Key considerations include:
- Data standardisation to ensure alerts are recorded in a consistent, machine-readable format
- Secure data transmission to protect sensitive operational information
- Role-based access control to ensure that only authorised stakeholders can view specific data
- Scalable data storage and processing to handle high volumes of real-time and historical data
The EU Battery Regulation emphasises interoperability, secure data access and lifecycle traceability, all of which support this type of integration.
Balancing real-time data flows with regulatory requirements and data privacy obligations is essential for successful implementation.
Challenges and Industry Readiness
Despite its potential, integrating BMS alerts with DBPs presents challenges. Many existing systems operate in silos, with limited interoperability between onboard electronics, enterprise platforms and external data systems.
There are also concerns around data ownership, cybersecurity and commercial sensitivity. Companies must define clear governance frameworks to manage how safety data is shared and used.
In addition, standardisation efforts are still evolving. Common data models and communication protocols will be needed to ensure that BMS alerts can be interpreted consistently across different platforms and stakeholders.
How BASE Supports Predictive Safety Through Digital Battery Passports
At the BASE project, safety is the core pillar of the Digital Battery Passport ecosystem. Our framework is designed to support structured, interoperable data integration across the battery lifecycle, including the potential linkage of real-time operational data such as BMS alerts.
By enabling secure data exchange, standardised data models and role-based access, BASE helps ensure that critical safety information can be captured, shared and analysed effectively. Our approach supports the development of predictive insights that can improve hazard detection, inform maintenance strategies and enhance lifecycle safety management.
BASE is also contributing to the evolution of data-driven safety practices in the European battery ecosystem through pilot implementations and collaboration with industry stakeholders.
Looking Ahead
Thermal runaway remains one of the most significant risks in battery systems, but advances in digital infrastructure are opening new possibilities for prevention. Linking BMS real-time alerts to the Digital Battery Passport creates a pathway for earlier detection, better data sharing and more informed decision-making across the value chain.
As the EU Battery Regulation moves towards full implementation, integrating operational safety data into passport frameworks will become increasingly important. Organisations that invest in these capabilities today will be better positioned to manage risk, protect users and meet evolving regulatory expectations.
The BASE project has received funding from the Horizon Europe Framework Programme (HORIZON) Research and Innovation Actions under grant agreement No. 101157200.
References
EUR Lex - Regulation (EU) 2023/1542: https://eur-lex.europa.eu/eli/reg/2023/1542/oj
European Commission – Battery demand and policy context: https://environment.ec.europa.eu/topics/waste-and-recycling/batteries_en
International Energy Agency – EU Sustainable Batteries Regulation: https://www.iea.org/policies/16763-eu-sustainable-batteries-regulation
TÜV Rheinland - EU New Battery Regulation (EU) 2023/1542: https://www.tuv.com/landingpage/en/eu-new-battery-regulation-eu-2023-1542/
European Union - Regulation (EU) 2023/1542 on Batteries and Waste Batteries: https://circular-cities-and-regions.ec.europa.eu/support-materials/eu-regulations-legislation/regulation-eu-20231542-batteries-and-waste-batteries
U.S. Department of Energy – Energy Storage Safety Strategic Plan: https://www.energy.gov/sites/default/files/2024-05/EED_2827_FIG_SafetyStrategy%20240505v2.pdf
National Laboratory of the Rockies – Modelling Lithium Ion Battery Safety: https://research-hub.nlr.gov/en/publications/modeling-lithium-ion-battery-safety-venting-of-pouch-cells-nrel-n/