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Peer-reviewedCC BY 4.0Batteries

Cross-Dataset Assessment of Electrical Loading, Thermal-Domain Evolution, and Abuse-Domain Separation in UAV-Relevant Lithium-Ion Batteries

  • Yuanzhe Li1,2
  • Ningning Wei1
  • Minghai Li2
  • Lei Huo3
  1. 1School of Energy and Mechanical Engineering, Dezhou University, Dezhou 253023, China
  2. 2School of Mechanical Engineering, Dalian Jiaotong University, Dalian 116028, China
  3. 3School of Materials Science and Engineering, Dalian University of Technology, Dalian 116024, China
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Abstract

Lithium-ion batteries in unmanned aerial vehicles (UAVs) experience highly dynamic electrical loads, but thermal warning criteria are rarely interpreted against non-abuse aviation-oriented operating states. This study integrated three independent datasets: 196 DJI Matrice 100 flights, 13,326 validated Sony-Murata VTC6 laboratory missions from 16 cells, and 67 high-temperature-rise abuse experiments from six cell/source families. Real UAV operation showed sustained electrical demand, with a median mission P95 power of 643.1 W; each additional 250 g payload was associated with a 51.1 W increase in P95 power. Among non-abuse missions, 942/13,326 (7.07%) reached at least 60 °C, and median mission maximum temperature increased by 14.28 °C from the first to final within-cell progression decile. However, the conservative maximum non-abuse heating rate at T ≥ 60 °C was 0.451 °C·s−1, below the minimum same-thermocouple value of 0.900 °C·s−1 in the abuse cohort. A literature-based criterion of T ≥ 60 °C and dT/dt ≥ 1 °C·s−1 produced no observed non-abuse activations and activated in 66/67 abuse experiments. Thus, temperature-domain overlap increased across recorded mission progression, whereas empirical thermal-rate separation persisted.

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Cite

BibTeXRIS
BibTeX
@article{li2026crossdataset,
  title = {{Cross-Dataset Assessment of Electrical Loading, Thermal-Domain Evolution, and Abuse-Domain Separation in UAV-Relevant Lithium-Ion Batteries}},
  author = {Yuanzhe Li and Ningning Wei and Minghai Li and Lei Huo},
  journal = {Batteries},
  year = {2026},
  month = oct,
  doi = {10.3390/batteries12110444},
  url = {https://www.mdpi.com/2313-0105/12/11/444},
  note = {CC BY 4.0},
}
RIS
TY  - JOUR
TI  - Cross-Dataset Assessment of Electrical Loading, Thermal-Domain Evolution, and Abuse-Domain Separation in UAV-Relevant Lithium-Ion Batteries
AU  - Yuanzhe Li
AU  - Ningning Wei
AU  - Minghai Li
AU  - Lei Huo
PY  - 2026
DA  - 2026/10/27
JO  - Batteries
DO  - 10.3390/batteries12110444
UR  - https://www.mdpi.com/2313-0105/12/11/444
AB  - Lithium-ion batteries in unmanned aerial vehicles (UAVs) experience highly dynamic electrical loads, but thermal warning criteria are rarely interpreted against non-abuse aviation-oriented operating states. This study integrated three independent datasets: 196 DJI Matrice 100 flights, 13,326 validated Sony-Murata VTC6 laboratory missions from 16 cells, and 67 high-temperature-rise abuse experiments from six cell/source families. Real UAV operation showed sustained electrical demand, with a median mission P95 power of 643.1 W; each additional 250 g payload was associated with a 51.1 W increase in P95 power. Among non-abuse missions, 942/13,326 (7.07%) reached at least 60 °C, and median mission maximum temperature increased by 14.28 °C from the first to final within-cell progression decile. However, the conservative maximum non-abuse heating rate at T ≥ 60 °C was 0.451 °C·s−1, below the minimum same-thermocouple value of 0.900 °C·s−1 in the abuse cohort. A literature-based criterion of T ≥ 60 °C and dT/dt ≥ 1 °C·s−1 produced no observed non-abuse activations and activated in 66/67 abuse experiments. Thus, temperature-domain overlap increased across recorded mission progression, whereas empirical thermal-rate separation persisted.
SN  - 2313-0105
ER  -