Fire protection monitoring of lithium battery charging stations – early detection of chemical processes with infrared thermal imaging technology

Abstract

The expansion of electrification and modern automation processes introduces entirely new types of elevated fire safety risks within the warehousing industry. Internal electrochemical degradation and failures occurring during the charging phase of lithium- ion batteries—such as dendrite propagation caused by improper operating conditions and subsequent internal micro-short circuits—can trigger an uncontrollable, self- accelerating exothermic chain reaction known as thermal runaway, resulting in explosive fires. Due to their inherently reactive nature, the response times of conventional smoke and heat detection systems are structurally insufficient for the timely detection of these processes, as their signaling is limited to the fully developed, advanced phases. This paper presents an integrated, predictive fire protection methodology based on Long-Wave Infrared (LWIR) thermal imaging diagnostics and intelligent Video Content Analysis (VCA) algorithms. This technology is capable of identifying abnormal temperature rises within milliseconds during the early latent phase (between 70–110 °C), well before the onset of gas generation (venting) or pyrolysis appear. The research thoroughly analyzes the practical benefits of bispectral image fusion, dynamic Region of Interest (ROI) zoning, and AI-based trend analysis. The outdoor case study and controlled burn test presented in the paper validate the efficacy of the thermal imaging system, which provides a significant time advantage over reactive systems by filtering out critical thermal anomalies at an early stage. Based on these findings, a structured automated intervention matrix eliminates human error, mitigating fire propagation through direct technological shutdown and emergency forced ventilation. In the event of a fully developed fire, the specific physical properties of the infrared spectrum provide effective tactical command support for firefighting forces by enabling vision through dense smoke and flames to precisely localize the fire core, thereby enhancing responder safety. Finally, the study addresses the economic validation of the investment and proposes future development vectors, such as the safety data fusion of thermal monitoring with internal Battery Management Systems (BMS).