Abstract

The increasing deployment of lithium-ion batteries in electromobility, industrial logistics, and stationary energy storage systems has introduced new operational safety challenges associated with thermal runaway, fire development, and the release of hazardous substances. Although significant attention has been devoted to battery design and fire suppression technologies, less emphasis has been placed on the development of integrated monitoring systems capable of identifying abnormal thermal behaviour during routine storage and handling operations. This paper presents an operational framework for the early detection of thermal anomalies in lithium-ion battery storage facilities based on the integration of thermal imaging technology, multi-level alarm logic, automated notification processes, and predefined response procedures. The proposed framework was developed using a risk-based approach and implemented within an industrial environment where lithium-ion batteries and battery modules are routinely stored and handled. The methodology included hazard identification, determination of critical monitoring zones, configuration of thermal detection devices, establishment of alarm thresholds, and integration with existing fire protection infrastructure. Particular attention was devoted to ensuring rapid identification, localization, verification, and escalation of abnormal thermal conditions before the occurrence of visible fire manifestations. The implemented monitoring framework comprised a total of 21 thermal imaging cameras, including four fixed radiometric thermal imaging cameras and seventeen local thermal monitoring cameras, covering five risk-prioritized monitoring zones within an industrial lithium-ion battery storage facility. During operational deployment, the system recorded 21 Yellow Alerts, 6 Red Alerts, and 4 false alarms, with an average response time of 4.2 min. Experimental verification further demonstrated that, although directly exposed battery modules were measured at approximately 60 °C, enclosure within the battery pack significantly attenuated the externally detectable thermal signature, with surface temperatures decreasing to approximately 23–31 °C after prolonged enclosure. The results demonstrate that the proposed framework enables continuous operational monitoring, supports timely identification of abnormal thermal behaviour, and provides a structured basis for rapid decision-making and emergency response in industrial lithium-ion battery storage facilities. The integration of thermal monitoring with structured alarm management and response procedures creates a comprehensive safety chain that contributes to reducing the probability of delayed incident recognition. The presented approach provides practical guidance for industrial operators seeking to improve lithium-ion battery safety and may serve as a foundation for the future development of operational safety requirements for battery storage facilities. The principal contribution of this study is the documented implementation and operational evaluation of an integrated thermal monitoring and response system under routine automotive production conditions.

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