Smart EV Battery Monitoring System and Fire Prevention System

Abstract

The rapid growth of electric vehicles (EVs) has increased the demand for intelligent battery management systems capable of ensuring operational safety, reliability, and extended battery life. Battery failures caused by overvoltage, undervoltage, overcurrent, overheating, and gas leakage can significantly degrade battery performance and may lead to hazardous incidents such as thermal runaway and fire. This paper presents a Smart EV Battery Monitoring and Fire Prevention System that continuously monitors critical battery parameters and provides real-time protection against abnormal operating conditions. The proposed system employs an ESP32 microcontroller integrated with voltage, current (ACS712), temperature, and MQ-2 gas sensors to acquire and process battery data. A Battery Management System (BMS) is incorporated to provide overcharge, over-discharge, and short-circuit protection, while a relay module disconnects the battery during critical conditions. The system also utilizes a cooling fan, buzzer, LCD display, and GPS module to enhance user safety through immediate alerts, thermal management, and location tracking. Experimental evaluation under normal operation and multiple fault scenarios—including over-temperature, over-voltage, under-voltage, and over-current conditions—demonstrated reliable fault detection, rapid response, and effective activation of protective mechanisms. The developed prototype successfully enhanced battery safety, minimized the risk of fire hazards, and improved system reliability through continuous real-time monitoring. Owing to its low cost, scalability, and IoT-enabled architecture, the proposed system is well suited for electric vehicles, e-bikes, battery energy storage systems, and other smart energy applications requiring continuous battery health monitoring and fire prevention.