Cost-Aware Multi-modal Multi-Fidelity Gaussian Process Fusion for Lithium-Ion Battery Pack Crash Damage Prediction

With the rapid development of new energy vehicles, fast and reliable prediction of power battery collision damage has become increasingly important. Traditional finite-element analysis is computationally expensive and difficult to deploy for rapid prediction under varying conditions. Although learning-based methods are faster, they usually rely on single-fidelity data: high-fidelity data is accurate but scarce and costly, while low-fidelity data is abundant but less reliable. Existing multi-fidelity methods alleviate this issue, yet often suffer from imbalanced sample allocation and weak cross-fidelity modeling. Moreover, current adaptive sampling strategies cannot dynamically determine the appropriate fidelity for different regions of the design space. To address these challenges, we propose HNGP-LCA, a multi-fidelity active learning framework for battery pack collision damage prediction. Our method consists of two components: (1) an Ensemble Nested Gaussian Process module that integrates single-layer and double-layer nested Gaussian process regression to better capture high–low fidelity correlations; and (2) a Location Information Cost-aware Active Learning strategy that leverages positional information to reconstruct expected improvement under different fidelities, enabling dynamic fidelity selection during sampling. Experiments on multiple synthetic benchmarks and a real battery pack engineering case demonstrate that HNGP-LCA achieves a better trade-off among accuracy, efficiency, and cost than strong baselines such as NARCO and MFBO. In the engineering case, it improves prediction accuracy by 0.6% over NARCO and 1.29% over MFBO, while reducing dependence on expensive high-fidelity data. These results show that HNGP-LCA provides an effective and practical solution for battery collision damage prediction.