New tech tracks EV battery health 1M times/sec while it’s in use

Researchers at Germany’s Fraunhofer Institute for Manufacturing Technology and Advanced Materials (IFAM), led by Professor Fabio La Mantia, have developed a novel real-time battery monitoring technique called dynamic impedance spectroscopy. Unlike traditional impedance spectroscopy, which requires batteries to be at rest and takes up to 20 minutes for results, this new method performs up to one million measurements per second during live operation. By overlaying a multi-frequency test signal onto the charging or discharging current, the system captures detailed data on the battery’s internal electrical behavior, enabling continuous tracking of state of charge (SoC), state of health (SoH), and safety. The innovation includes specialized algorithms that efficiently process the massive data volume in real time without losing accuracy. This allows battery management systems to detect overheating instantly and take preventive actions such as power reduction or shutdown, eliminating reliance on slower external temperature sensors. The technology enhances electric vehicle (EV) charging by optimizing between fast and slow charging modes to reduce battery wear and overheating. Additionally,