A Non-Invasive Optical Sensor for Real-Time State of Charge and Capacity Fading Tracking in Vanadium Redox Flow Batteries

Accurate and real-time state of charge (SOC) monitoring is critical for the safe, efficient, and stable long-term operation of vanadium redox flow batteries (VRFBs). Traditional monitoring methods are susceptible to errors arising from side reactions, cumulative drift, and electrolyte imbalance. This study develops a non-invasive optical sensor module for the negative electrolyte (anolyte), utilizing the favorable spectral properties of V(II)/V(III) ions at 850 nm for real-time SOC tracking. A fifth-order polynomial model was employed for calibration, successfully managing the non-linear optical response of highly concentrated electrolytes and achieving exceptional accuracy (adjusted R2 > 0.9999). The optical sensor reliably tracked capacity degradation over 50 galvanostatic cycles, yielding a degradation curve that showed a high correlation with the conventional coulomb counting method, thus confirming its feasibility for assessing battery’s state of health. Contrary to initial expectations, operating at higher current densities resulted in a lower capacity degradation rate (CDR). This phenomenon is primarily attributed to the time-dependent nature of parasitic side reactions. Higher current densities reduce the cycle duration, thereby minimizing the temporal exposure of active species to degradation mechanisms and mitigating cumulative ion imbalance. This mechanism was corroborated by physicochemical analysis via UV-Vis spectroscopy, which revealed a strong correlation between the severity of spectral deviation and the CDR ranking. This non-invasive optical technology offers a low-cost and effective solution for precise VRFB management and preventative maintenance.