Aging

Most battery models fail not because the equations are wrong — but because the assumptions smuggled in with them are wrong. Fifteen years working with battery models across the stack: from ECM spreadsheets that needed to survive a BMS real-time loop, to full electrochemical models trying to capture what actually happens inside the cell during a fast charge. The gap between “runs on paper” and “works in a vehicle” is where most of the interesting problems live. ...

A battery’s safe operating envelope is not a fixed number. It’s a surface — varying continuously with temperature, state of charge, state of health, and operating history. Getting it wrong in the conservative direction costs performance and range. Getting it wrong in the aggressive direction costs cell life, and at the extreme, safety. The Current Limits Generator was built to define that surface correctly — from physics, not from conservative blanket rules. ...