Abstract: Lithium-ion batteries have been used in batteries of electric vehicles, consumer electronics, and industrial test devices in a large degree because of their large energy density and their charging ability for many times. Cyclic and repetitive testing Environmental conditions the Charge Discharge Charge (CDC) testing environments expose the batteries to repeated cycling, large current loads, intense and many state-of-charge transitions, and very high thermal and electrochemical stress levels. Such conditions enhance a threat of thermal runaway that is a severe safety issue that involves the uncontrolled heat generation resulting in a fire or an explosion. In this paper, the phenomenon of thermal runaway in the work of lithium-ion batteries in CDC condition has been developed in detail. The experimental assessment was then repeated at various C-rates and ambient temperatures using real-time interactive thermal imaging, embedded thermocouples, and philosophical voltagecurrent in determining the initial signs of C - indication of thermal inconsistency. The paper also suggests a whole set of passive temperature control and active change on the battery management system (BMS), such as the dynamical feedback control on the temperature, active current control and the outlier forecasting etc. The findings indicate that the traditional BMS protection plans cannot be used in long-term situations of CDC testing. The suggested multilayer prevention approach is an efficient tool that will eliminate the threat of thermal runaway and enhance operational safety and test reliability. The results set a practical idea on how to test batteries more safely, and their practical advice can be used in longer-term solutions to a larger-scale approach to improving thermal performance in real-world lithium-ion based battery systems.

Keywords: Lithium-ion batteries; Thermal runaway; Charge–discharge cycling; Battery management system; Thermal monitoring; Energy storage safety.

Downloads: | DOI: 10.17148/IARJSET.2026.133111