🎯 Project Requirements & Targets MASTER INPUT - feeds all modules
Define all project targets here first. All Engineering tabs, TVR, DVP Intake and Battery Testing auto-read from this sheet.
① Project Setup
📁 Project Information
e.g. EU, US, CN, IN, JP - drives certification requirements
🚗 Vehicle / Application Type MASTER
🏍️
2-Wheeler
E-bike / Moto
🚗
4-Wheeler
Passenger EV
🚌
Bus
Transit
🚛
Truck / HCV
Commercial
🏭
Industrial / AGV
Forklift / Crane
🌾
Ag Tractor
Farming
⚙️
Other / Custom
Marine / Rail
② Energy & Capacity
🔋 Pack Energy Targets
Minimum gross pack energy required
1.0 = 0–100% · 0.8 = 10–90% SoC window
⚡ Energy Density
Pack-level target (not cell-level)
System weight constraint
Packaging envelope constraint
🔌 Voltage Architecture
Min pack terminal voltage at full discharge
Max pack terminal voltage at full charge
③ Electrical Performance
⚡ Discharge Power
Sustained peak for 10 min, e.g. hill climb
🔌 Charging Performance
Cell datasheet limit - flows to Charging tab
④ Thermal System
🌡️ Operating Temperature
BMS protection threshold
Max ΔT across pack at steady state
💧 Cooling System
Pre-conditioning / cold climate heating
🌡️ Storage Conditions
Typically 30% per UN 38.3 transport
⑤ Environmental & Safety
🌍 Environmental Requirements
Sets test severity for water ingress testing
Max operating altitude - affects HV creepage clearance
Test Requirements - blank = not specified
| Test Type | Requirement / Spec |
|---|---|
| Vibration | |
| Salt Fog / Corrosion | |
| Shock | |
| Drop / Crush |
🎯 Extended Check Targets
← thresholds used in Target vs Results · Extended Checks table
Edit these limits to match your project specification. They feed directly into the Extended Checks pass/fail table.
Resistance check - Pack IR at BoL must be ≤ this
DCIR check - EoL/BoL IR ratio must be ≤ this
DCIR check - voltage drop at −10°C/20%SoC/I_peak
BMS check - V_max − V_min must be ≥ this
Precharge check - RC time constant ≤ this
HV Safety - IEC 6469-1 voltage class for your pack
Charging check - T_chg_hi − T_chg_lo must be ≥ this
Energy check - SoC headroom at 90%SoC regen point
⚠️ HV Safety Requirements
Per IEC 60664-1 - auto-calculated from V_max
GB 38031 / UN GTR 20: ≥5 min occupant warning
📜 Certification Requirements
Enter applicable standards manually. Leave blank if not yet determined - blank fields are treated as pass in compliance checks.
Primary safety standard(s) for your markets
⑥ Lifetime & Reliability
📈 Cycle & Calendar Life
🔩 Durability & BMS
BMS target SoC accuracy RMS
⑦ Business & Cost
💼 Cost Targets
System-level pack cost including BMS, housing, cooling
⑧ Target Compliance Overview
✅ Target Compliance Overview
🔬 Cell Inputs Configuration
All cell parameters propagate automatically to Energy, Voltage, Thermal, Resistance, and all other modules.
Cell Parameters Auto-propagates everywhere →
DCIR at 25°C, 50% SoC, 1C pulse
📄 Cell Datasheet Auto-Extract
📂 Upload cell datasheet (PDF or TXT) - auto-extracts key parameters
Supports: Capacity, Voltage, IR, Mass. Review extracted values before continuing.
Supports: Capacity, Voltage, IR, Mass. Review extracted values before continuing.
📈 OCV–SoC - All Temperatures (V)
📂 Upload CSV
DoD Target:
(0–1, links from Energy tab)
SoC
0°C
25°C
(%)
°C
(fixed)
(fixed)
°C
| 0 | |||||
| 10 | |||||
| 20 | |||||
| 30 | |||||
| 50 | |||||
| 70 | |||||
| 80 | |||||
| 90 | |||||
| 95 | |||||
| 100 |
Pack Architecture
Derived Pack Specifications
Target vs Result
Chemistry Reference
📈 OCV–SoC Curve
━ T_min
━ 0°C
━ 25°C
━ T_max
│
━ DoD window
⬛ outside DoD
🏆 Cell Qualification Scorecard
OEM gate-check: auto-validates supplier cell datasheet values against your project targets. 16 checks across voltage, energy, C-rate, impedance, thermal, lifetime and certification. Go/No-Go verdict.
⚙️ S×P Sizing Calculator
Evaluates all valid configurations against constraint matrix. Click row to apply to Cell Inputs.
🌡️ DCIR Map - Cell & Pack Resistance vs T & SoC
Upload cell supplier Excel or enter manually. 25°C/50%SoC baseline auto-pushes to Cell Inputs.
📉 Temperature Derating - Power vs T_cell
Discharge & charge derating curves. Auto-reads P_peak and T_cell_max from Project Targets.
🔌 Fuse & Circuit Protection Selector
Auto-recommends main fuse, MSD rating, voltage class and type. IEC 60269-4 · SAE J1495 · ISO 8820.
🔋 Usable Energy & Derating
Cell inputs auto-pulled from Cell Inputs tab. Target indicators update vs Project Targets.
Derating Factors
E_usable = E_gross × DoD × Î·_sys × f_BOL × f_balance × f_voltage × f_design × f_temp
From Project Targets DoD field · 1.0=full window, 0.8=10–90% SoC · adjusts OCV chart window
Typical: 0.97–0.99. From datasheet at 1/3C @25°C.
5 mV imbalance, 12 mV/%SoC → typical 0.988
12 mV/%SoC, ±7 mV accuracy → typical 0.988
@25°C=0.98 · @10°C=0.97 · @−15°C=0.95
1.0 if TMS active. Apply only for unconditioned packs.
Energy Results vs Targets
Factor Loss Waterfall
⚡ Voltage Window & Configuration
System voltage validated against Project Target limits. Highlights valid S configurations.
Voltage Inputs (auto-filled from Cell tab)
Number of cell groups (stacks) in series. Min value: V_sys_min / (cells_per_stack × V_cell_max). From: target voltage window & cell voltage limits.
Max value: V_sys_max / (cells_per_stack × V_cell_min). Practical limit: pack physical size constraint.
Validated Configuration
Voltage Window
Strings Configuration Matrix - V range per S count
🌊 Current & Power Analysis
Load profile inputs. Ambient temperature adjustable - results update live.
Load Profile Inputs
P_total = P_hydraulic/(η_m·η_inv) + P_traction/(η_m·η_inv) + P_TMS + P_aux/η_dcdc
I_bat = P_total / V_nom | C-rate = I / Q_Ah
25°C
Main Drive
ℹ️ Ambient temperature affects results: each ±10°C change modifies power demand by ~5–8% through TMS load and efficiency changes. Cold ambient increases TMS heating; hot increases compressor/cooling load.
Traction
Auxiliary & iTMS Cooling
Any other HV consumers: work lights, attachments, compressor, pump, etc.
Current & Power Results
Power Breakdown
━ T_min
━ 0°C
━ 25°C
━ T_max
Efficiency Map - Target vs Result
Temperature Sensitivity Matrix
🌡️ Thermal Management System (TMS)
Pack config auto-selected from Cell Inputs. Load case can be customised or upload a duty cycle CSV.
Load Case Selection
📂 Click to upload duty cycle CSV
Columns: time_s, power_kW
Columns: time_s, power_kW
TMS Inputs (Auto from Cell tab where noted)
Heat transfer coeff cell→housing→air. From temp. limits sheet: 30 W/K
50% glycol–water mix: 3400 J/kg·K
Heater / Pre-conditioning
TMS Results
Thermal Balance
TMS Set-Point Logic (standard)
Cooling Plate Pressure Drop Calculator
Re = ÏvD/μ | If Re<2300: laminar (f=64/Re) | Else turbulent (Swamee-Jain)
ΔP = f × (L/D) × Ïv²/2 [Pa] → convert to mbar ÷100
Total coolant path length in plate
Cooling System Properties
🔌 Charging Analysis
Charging Inputs
V_avg = S × (OCV_10 + OCV_90)/2
I_charge = P_charger / V_avg
C-rate = I / Q_Ah
t_charge = E_usable / P_charger
Set in Project Targets → Charging · auto-linked here
Charge Results vs Targets
Charge Time vs Charger Power
Charge Time vs Charger Power - Table
📈 Lifecycle, SoH & Calendar Life
Lifecycle Inputs
SoH(n) = 1 − (n/N_life) × (1 − SoH_EoL)
Life_years = min(N_cycles / cycles_per_year, calendar_target)
E_net = E_usable × (1 + η_regen × f_regen) [regen credit]
Autonomy = E_net × SoH / P_avg_net [hours]
P_avg_net = P_avg × (1 − η_regen × f_regen) [net demand]
Average traction + auxiliary load kW before regen credit. For excavator ~8–15kW avg. Upload duty cycle in Drive Cycle tab for accuracy.
% of consumed energy recovered via regenerative braking. Off-highway: 0–15%. Road vehicles: 15–35%. Excavator boom-down: up to 25%.
Round-trip efficiency of regen path: motor→inverter→battery. Typical 80–90%.
Used to convert cycle life → operating hours. Full workshift = 8–10h.
Optimal for calendar life: 30–60%
Lifecycle Results vs Targets
SoH & Autonomy
━ SoH%
━ Autonomy (h)
- - EoL target
- - Autonomy target
SoH Trajectory Table
🔬 Pack Resistance - Component Build-Up
Technical resistance model built from sub-component parameters, contact types, and geometry. Based on standard resistance calculation methodology.
Cell Tab Contact Resistance Model
R_contact = Ï/(A×n) × Kc × Ks × Kp × Kw × (1 + α×ΔT)
where: Kc=constriction, Ks=surface, Kp=porosity, Kw=weld efficiency
Busbar
Contact Factors
1.5–3.0 (typical: 2 = welded/pressed)
1=bare, 1.5=plated
1.1–1.3 typical
0.01–0.05 (good weld = 0.03)
Pack Architecture Counts (← from Cell tab)
Pack Resistance Build-Up
Additional HV Path Components
Add any combination of: contactor, fuse, wiring harness, connector, shunt, precharge resistor. Values will be added to total pack resistance.
Extra Components Total
BoL vs EoL Comparison
Material Conductivity Reference
⚙️ Precharge Resistor Calculation
Selects resistor based on capacitance, pack voltage, time, current limit, and leakage - outputs energy rating and contactor inrush check.
Precharge Inputs
Ï„ = t_pre / n → R = Ï„ / C (by time constant)
R = V_bat / I_max (by peak current limit)
R = (1−α)·V_bat / I_leak (by leakage)
R_sel = max(R_by_time, R_by_Imax, R_by_leak)
Vc(t) = V_bat × (1 − e^(−t/Ï„))
I_main_inrush = (V_bat − Vc_final) / R_main_total
Total DC bus capacitance of connected load (inverter, DC-DC, motor drive). Typical: 0.5–5 mF.
n=5 → 99.3% of V_bat. n=3 → 95%. IEC 60947 standard uses n=5.
Close main contactor when Vc ≥ α × V_bat. 0.95–0.99 typical.
Sets minimum R = V_bat/I_max. Protects precharge resistor from overcurrent. Set 0 to ignore this constraint.
Maximum allowable leakage through precharge path (isolation monitoring concern).
Total series resistance when main contactor closes: contactor Rce + wiring resistance. Typical 1–5 mΩ. Used for inrush calculation at contactor close.
From contactor datasheet. e.g. Sensata AMETEK: 500A, Tyco EV200: 700A, TE Kilovac: 700A.
Engineering target for inrush current when main contactor closes. Typical: 10–50A. Rule of thumb: <10% of contactor I_rated (e.g. 50A for 500A contactor). Lower = better for contactor life. Depends on capacitor charge level at close, bus capacitance, and cable resistance.
Max energy allowed at contactor close: E = ½CV²_delta. Keep below contact rating. Typical 0.01–0.1J. Set 0 to ignore.
Recommended ≥1.5× E_res for resistor pulse rating.
Precharge Results
Capacitor Charge Curve (0 to t_end)
Show 0 →
3s
🟢 Voltage curve · 🟡 α threshold · 🟠 t_pre marker · 🔵 I_min voltage limit
🗺️ Battery & ePT Power Map
Define operating modes with power and duration. Chart shows envelope + time profile vs targets.
⚡ Voltage Window
🔋 Power Modes
Mode
kW
Time (s)
● Cont. Discharge
● Peak Discharge
● DC Charge
● AC Charge
📐 Limits
I×V hyperbola on P vs V chart
🎯 Targets
Excavator: 30s · Bus: 60s · Truck: 120s · Industrial: 300s
📊 vs Target
⚙️ Operating Point
Power Envelope
ePT Efficiency Breakdown
📋 Engineering Result - Power Envelope Analysis
🛡️ Safety, Fusing & Protection Sizing
Protection Sizing
I_fuse ≥ 1.25 × I_peak_30s
R_precharge → see Precharge tab
I_sc = V_pack / (R_int + R_ext_min)
A_cable = 2ÏL × I_cont / V_drop
Fusing & Cable Results
Protection Chart
📜 Applicable Standards ← filtered from Standards database by application
🚗 Drive Cycle / Work Cycle Analysis
Upload CSV or enter points manually. Live chart shows Time vs Power / Voltage / Current.
Upload Work Cycle
CSV format: time_s, power_kW (one row per timestep)
Optional col 3: voltage_V or speed_kmh
📊 Upload work cycle Excel or CSV
Col A=time_s · Col B=power_kW · Col C=voltage_V (optional)
Col A=time_s · Col B=power_kW · Col C=voltage_V (optional)
Manual Entry - Time vs Power
Enter cycle points below. Click + to add rows. Chart updates live.
Quick stats
Time-weighted avg from cycle data
📊 Cycle Analysis Results
Upload a CSV or add points above
Energy Budget
Drive Cycle
━ Power (kW)
━ Pack Voltage (V)
━ Current (A)
- - P_avg target
🌡️ Thermal Rise Analysis - Drive Cycle Linked
🔗 Waiting for cycle data
Temperature rise is computed at every drive cycle timestep using cell-level I²R heat generation,
thermal mass, TMS cooling capacity, and ambient conditions. Adjust inputs below and click Run Thermal Simulation.
Cell Inputs Thermal
Starting temp at t=0
Surrounding environment
m×Cp - total heat capacity. Auto-fills from Cell tab.
Pack IR = c_ir_bol × S / P (mΩ). Auto-fills from Cell tab. e.g. 0.22 × 112 = 24.6 mΩ
TMS Cooling System
Active coolant flow when TMS running
Temperature of coolant entering pack
Housing-to-air natural convection coefficient
TMS turns ON when cell temp exceeds this
TMS turns OFF when cell temp drops below this (hysteresis)
Limits & Thresholds
BMS begins power derating above this
Hard shutdown threshold
Onset of thermal runaway - critical limit
🧠 BMS Design & Specification
BMS parameters, algorithms, fault thresholds, communication. Linked to Cell, Safety, and Lifecycle tabs.
Measurement & Sensing
Auto-filled: V_max (${S.c_vmax||3.65}V) − V_min (${S.c_vmin||2.0}V) = operating window. Used to size ADC resolution.
Typical: ±3mV. Affects f_voltage derating.
±1°C typical for NTC @-15 to 60°C
<1% required for good SoC accuracy
Fault Thresholds (← auto-linked from Cell tab)
← From Cell V_max. Add 10–30mV safety margin.
← From Cell V_min + 0.5V margin recommended
← From Target T_cell_max
← From Target T_op_min
← 1.1× max continuous current
Algorithms & SoX
2% at 0–35°C, 3% outside - industry standard
Start balancing when cell Vmax−Vmin > threshold
Communication
CC-CV Charge Profile
CC phase: charge at constant I_cc until V_max reached
CV phase: hold V_max, taper until I < I_cutoff
t_charge ≈ E_usable / (I_cc × V_avg) + CV tail
Typically C/10 (10% of CC current)
🔩 Busbar Design - CSA, Creepage & Clearance
Busbar cross-section, current density, IEC 60664 creepage and clearance - with pass/fail decision for each check.
① Busbar Geometry & Material
R = Ï × L / (W × T) × (1 + α×ΔT)
J = I / (W×T) [A/mm²] → must be ≤ J_limit
ΔT_rise = I² × R / (surface × h_conv)
ΔT = T_busbar_max − T_ambient. Standard: 40°C Cu, 30°C Al (IEC 61439).
Working voltage - determines IEC 60664 creepage/clearance class.
② Creepage & Clearance Inputs IEC 60664-1
Measured physical creepage path on your PCB/busbar design.
Measured physical air gap between conductors at different potential.
Calculated Values
✅ Design Validation - PASS / FAIL
📐 IEC 60664-1 Quick Reference
PD2, OV Cat III - most common EV battery application
| Voltage (V) | Creepage (mm) | Clearance (mm) |
|---|---|---|
| ≤ 50 | 0.8 | 0.4 |
| ≤ 150 | 1.4 | 0.7 |
| ≤ 300 | 2.5 | 1.5 |
| ≤ 600 | 5.0 | 3.0 |
| ≤ 1000 | 8.0 | 6.0 |
Current Density J limits (IEC 61439)
| Cooling | Cu (A/mm²) | Al (A/mm²) |
|---|---|---|
| Natural convection | ≤ 3 | ≤ 2 |
| Forced air | ≤ 5 | ≤ 3 |
| Liquid cooled | ≤ 8 | ≤ 5 |
📊 Project Data Hub & Gap Analysis
Upload data, mark availability, and see which calculations need more inputs. All uploaded data auto-populates connected tabs.
🔬 Cell Data
Cell Datasheet (V, Ah, IR, Cp) Required
📂 Upload PDF/TXT datasheet → auto-extract to Cell tab
← Feeds: Cell Inputs tab (V_nom, V_max, V_min, Ah, mass, IR)
Full OCV–SoC Curve (10+ points) Required
📂 Upload OCV–SoC CSV (soc%, ocv_V) → auto-fills OCV table in Cell tab
← Feeds: Charging tab V_avg, BMS CC-CV profile, Energy derating
DCIR vs SoC/Temperature Map Required
📂 Upload DCIR CSV (temp°C, soc%, dcir_mΩ) → fills resistance map
← Feeds: Resistance tab, BMS SoP calculation, Thermal heat load
Capacity vs C-rate (Peukert Curve) Required
📂 Upload CSV (crate, capacity_Ah) → Peukert derating
← Feeds: Energy derating f_design, Lifecycle autonomy at high C-rate
Capacity Fade Curve (SoH vs Cycles) Required
📂 Upload CSV (cycles, soh_percent) → SoH trajectory
← Feeds: Lifecycle tab SoH trajectory, Autonomy @5yr/10yr
🌡️ Thermal Data
Drive / Work Cycle Duty Profile Required
📂 Upload CSV (time_s, power_kW) → avg/peak power → TMS sizing
← Feeds: Current tab P_avg, Thermal tab heat load, Power Map
Cooling Plate Pressure Drop Curve Optional
← Feeds: Thermal tab ΔP check. Use Thermal tab calculator if not available.
⚡ Electrical Data
CC-CV Charge Profile Required
📂 Upload CC-CV profile CSV (time_s, current_A, voltage_V)
← Feeds: Charging tab, BMS CC-CV section, Thermal charge heat load
HV Electrical Architecture Diagram Required
📂 Upload HV architecture image or PDF
Precharge Design (R, C values) Required
← Enter in Precharge tab - R, C, α, I_max automatically calculated
🧠 BMS Data
SoC Estimation Algorithm Required
← Feeds: BMS tab algorithm selection + expected accuracy
SoH Estimation Model Required
← Feeds: Lifecycle SoH trajectory, BMS tab
SoP (State of Power) Calculation Optional
← Feeds: Power map limits, Current tab derating factors
Cell Balancing Strategy & Energy Required
← Feeds: Energy tab f_balance factor, Usable energy calc
Fault Thresholds (OV/UV/OT/OC) Required
← Auto-linked from Cell tab V_max/V_min + Temperature targets
📦 Pack Design
Pack CAD / Space Claim Required
📂 Upload STEP/STL/image → view in 3D Viewer tab
Busbar Design (CSA, creepage) Required
← Calculate in Busbar tab. Enter geometry below to auto-calculate.
Thermal Resistance Network (Rth) Required
← Feeds: Thermal tab h_air coefficient, Q_to_coolant split
🛡️ Safety Data
FMEA / Safety Analysis Required
📂 Upload FMEA document (Excel/PDF)
Thermal Runaway Prevention Design Required
Gas detection, vent routing, cell-to-cell propagation barrier
IMD (Insulation Monitoring) Design Required
← Feeds: Safety tab compliance checklist
📋 Regulatory
UN 38.3 Test Plan Required
📂 Upload UN 38.3 test plan or certificate
IEC 62619 Test Protocol Required
📂 Upload IEC 62619 test protocol or certificate
Functional Safety Analysis Optional
ISO 25119 (off-highway) or ISO 26262 (road vehicles)
💼
Business & Cost → dedicated sheet
BOM breakdown and TCO comparison have moved to the 💼 Business & Cost tab in the nav bar above.
Project Data Completeness
Next Recommended Actions
💼 Business & Cost Analysis
Full BOM with manual component entry, overhead, profit margin. TCO comparison vs ICE / diesel-electric alternative.
📦 Bill of Materials - Component Cost
Total BOM = Σ components + fixed costs + overhead + profit margin
Core Components
= $3,440 at 43 kWh
Additional Components
Add any extra components - connectors, sensors, safety devices, enclosures, etc.
| Component | Cost ($) | Qty | |
|---|---|---|---|
Fixed Costs & Overhead
Factory overhead on direct costs
Gross margin target
⚡ TCO vs ICE / Diesel-Electric Alternative
Annual saving = ICE fuel cost/yr − EV electricity cost/yr + maintenance saving
Payback = Total BOM / Annual saving
ICE Reference Vehicle
EV Battery System
Auto-filled from BOM total above
BOM Cost Summary
Cost Breakdown
🏆 Target vs Results - Decision Sheet
All engineering targets compared against calculated results. Instant GO / CAUTION / NO-GO verdict per module.
-
✓ Pass
-
⚠ Caution
-
✗ Fail
RUN CHECKS
Overall Verdict
| Parameter | Module | Target | Result | Margin | Status | Notes |
|---|
📝 Engineering Decision Notes
🔲 3D Pack / Component Viewer
Upload any 3D file (STL, OBJ, GLTF/GLB) to view your battery pack or component design. Orbit · Zoom · Pan · Measure distances.
📂 Upload 3D File
Supported formats:
• STL - most common CAD export
• OBJ - Wavefront, with MTL colours
• GLTF / GLB - full materials + hierarchy
• STEP / STP - convert to STL in your CAD tool first
• STL - most common CAD export
• OBJ - Wavefront, with MTL colours
• GLTF / GLB - full materials + hierarchy
• STEP / STP - convert to STL in your CAD tool first
Or load a demo:
🎨 Display
Material colour
Opacity
📷 Camera
📏 Measure
Click two points on the model surface to measure distance. Units match model scale.
ℹ️ Model Info
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