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A Systematic Review of Battery Digital Twins for Thermal Safety, State Estimation, and Remaining Useful Life Prediction towards Predictive Maintenance

Publication Type : Journal Article

Publisher : Elsevier BV

Source : Results in Engineering

Url : https://doi.org/10.1016/j.rineng.2026.113958

Keywords : Battery Digital Twin, Thermal safety, State estimation, RUL prediction, EV industries, Sustainable development

Campus : Coimbatore

School : School of Engineering

Department : Mechanical Engineering

Year : 2026

Abstract : Cyber-physical systems in the e-transportation era have emerged as an advancement in the Electric Vehicle (EV) industry. Batteries are a prominent research product of EVs, driving progress towards the saturation of Industrial Revolution 5.0 by enhancing their efficiency, performance, and safety criteria. The current study provides a detailed survey on the implementation of Digital Twin Technology (DTT), a cyber-physical system in EV batteries. Battery Digital Twins (BDTs), which couple a physical battery with a continuously updated virtual counterpart, are widely proposed for this purpose; however, existing reviews rarely evaluates the level of BDT. This review addresses one central question: the extension of BDT implementations that satisfy the defining requirements of a digital twin while delivering the three functions on which predictive maintenance depends, namely thermal safety, state estimation and Remaining Useful Life (RUL) prediction. The review contributes an operational BDT definition and maturity classification, a reproducible evidence base and a research agenda prioritizing field-data validation, uncertainty-aware RUL prediction, bidirectional synchronization, interoperability and cybersecurity, with implications for researchers, battery manufacturers, fleet operators and digital-twin developers, thereby contributing to Sustainable Development Goal 7 (SDG-7).

Cite this Research Publication : S Sunantha, Thangamuthu Mohanraj, D Senthilkumar, A Systematic Review of Battery Digital Twins for Thermal Safety, State Estimation, and Remaining Useful Life Prediction towards Predictive Maintenance, Results in Engineering, Elsevier BV, 2026, https://doi.org/10.1016/j.rineng.2026.113958

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