Embedded Sensor Data Fusion and TinyML for Real-Time Remaining Useful Life Estimation of UAV Li Polymer Batteries

The accurate real-time estimation of the remaining useful life (RUL) of lithium-polymer (LiPo) batteries is a critical enabler for ensuring the safety, reliability, and operational efficiency of unmanned aerial vehicles (UAVs). Nevertheless, achieving such prognostics on resource-constrained embedded platforms remains a considerable technical challenge. This study proposes an end-to-end TinyML-based framework that integrates embedded sensor data fusion with an optimized feedforward neural network (FFNN) model for efficient RUL estimation under strict hardware limitations. The system collects voltage, discharge time, and capacity measurements through a lightweight data fusion pipeline and leverages the Edge Impulse platform with the EON™Compiler for model optimization. The trained model is deployed on a dual-core ARM Cortex-M0+ Raspberry Pi RP2040 microcontroller, communicating wirelessly with a LabVIEW-based visualization system for real-time monitoring. Experimental validation on an 80-gram UAV equipped with a 1100 mAh LiPo battery demonstrates a mean absolute error (MAE) of 3.46 cycles and a root mean squared error (RMSE) of 3.75 cycles. Model testing results show an overall accuracy of 98.82%, with a mean squared error (MSE) of 55.68, a mean absolute error (MAE) of 5.38, and a variance score of 0.99, indicating strong regression precision and robustness. Furthermore, the quantized (int8) version of the model achieves an inference latency of 2 ms, with memory utilization of only 1.2 KB RAM and 11 KB flash, confirming its suitability for real-time deployment on resource-constrained embedded devices. Overall, the proposed framework effectively demonstrates the feasibility of combining embedded sensor data fusion and TinyML to enable accurate, low-latency, and resource-efficient real-time RUL estimation for UAV battery health management.