I've been noticing that on large maps, if MAI have to travel to the opposite end, it's not uncommon that they can become incapacitated and explode from lack of "sleep". It would seem the pawn AI doesn't really seem to care whether they can travel to a location and back before bedtime... or maybe it's a low priority in the default pawn AI, since normal pawns don't self-destruct when past curfew. Or it could just be the relatively recent winter patch, and snowfall screwing with the pawn AI's travel time predictions.
In any case, I'm wondering if you ever considered increasing increasing the MAI battery lifespan (i.e., making them need to sleep less often), or even forgoing sleep entirely? You could even add a work speed penalty to compensate, so MAI units will still get the same amount of work done daily even if they sleep less or not at all.