How do you calculate usable capacity-graded cells?

Multiply cells per cycle by available cycles for gross output, then multiply by tester uptime and acceptable bin yield. With 900 cells/cycle over 24 cycles at 91% uptime and 95% yield, gross is 21,600 and usable is 18,673 cells.

Why is usable output lower than gross screening output?

Two losses cut it down: tester downtime removes 1,944 cells and cells falling outside usable capacity bins remove about 983 more, taking 21,600 gross down to 18,673 usable.

What is a good capacity-bin yield?

Mature cell lines often run 93-98% into acceptable bins; the 95% default is typical. Lower yields signal a wide capacity distribution from formation or coating variation that should be fixed upstream.

How does tester uptime affect graded output?

Uptime scales output directly — at 91% you lose 9% of gross, here 1,944 cells, before any yield loss. Raising uptime to 95% would recover roughly 860 cells per shift in this example.

Capacity grading vs IR or voltage sorting?

Capacity grading bins cells by usable amp-hours for energy matching, while IR or voltage sorting screens internal resistance or open-circuit voltage. Full cell sorting often applies all three, but this tool models the capacity-grading throughput.

How do I increase usable graded cells?

Add grading cycles or cells per cycle to raise gross output, lift tester uptime, or tighten upstream process control so more cells land in acceptable bins. Each lever pushes the 18,673 figure higher.

EV & Battery Manufacturing calculator

Cell Capacity Variation Sorting Capacity Calculator

This calculator estimates how many cells you can actually grade and bin by capacity in a given period, after tester downtime and bin-yield losses. Capacity grading sorts cells into tight capacity bins so packs are built from matched cells — critical for pack energy, balancing and warranty life. Cell-sort and test engineers use this number to plan tester banks, schedule pack-build feed, and size finished-cell inventory. Because grading equipment has real uptime limits and not every cell lands in an acceptable bin, gross screening output always overstates usable output, so this metric strips both losses out to give a realistic graded-cell count.

What this calculator does

Estimate usable capacity-screening output from cells per grading cycle, available cycles, tester uptime, and acceptable bin yield.
a grading or test team needs to know whether capacity screening can keep up with formation and module assembly
It computes usable capacity-graded cells by multiplying gross screening output by tester uptime and acceptable bin yield.

Formula used

Gross capacity-screening output = cells per grading cycle × available grading cycles
Usable capacity-graded cells = gross output × tester uptime × acceptable bin yield

Inputs explained

Cells screened per grading cycle:
Available grading cycles:
Capacity tester uptime:
Acceptable capacity-bin yield:

How to use the result

Use it to plan grading capacity, feed pack build with matched cells, or size tester banks for a target cell volume.
It uses single average values for uptime and yield; in reality both vary by cell chemistry, age and tester health, and very wide capacity distributions can drive bin yield below the figure you enter.

Current U.S. benchmarks

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Common questions

How do you calculate usable capacity-graded cells? Multiply cells per cycle by available cycles for gross output, then multiply by tester uptime and acceptable bin yield. With 900 cells/cycle over 24 cycles at 91% uptime and 95% yield, gross is 21,600 and usable is 18,673 cells.
Why is usable output lower than gross screening output? Two losses cut it down: tester downtime removes 1,944 cells and cells falling outside usable capacity bins remove about 983 more, taking 21,600 gross down to 18,673 usable.
What is a good capacity-bin yield? Mature cell lines often run 93-98% into acceptable bins; the 95% default is typical. Lower yields signal a wide capacity distribution from formation or coating variation that should be fixed upstream.
How does tester uptime affect graded output? Uptime scales output directly — at 91% you lose 9% of gross, here 1,944 cells, before any yield loss. Raising uptime to 95% would recover roughly 860 cells per shift in this example.
Capacity grading vs IR or voltage sorting? Capacity grading bins cells by usable amp-hours for energy matching, while IR or voltage sorting screens internal resistance or open-circuit voltage. Full cell sorting often applies all three, but this tool models the capacity-grading throughput.

Last reviewed 2026-05-12.