EV & Battery Manufacturing worked example

Cell Stack Alignment Spec Window with measured stack alignment offset of 0.45 mm: a worked example

Push measured stack alignment offset up to 0.45 mm and the picture changes. This example computes every intermediate figure at that operating point. a cell assembly engineer needs a quick in-window check for stack, jelly roll, or lamination alignment

The inputs for this scenario

  • Measured stack alignment offset: 0.45 mm (raised for this scenario; the documented default is 0.18)
  • Lower alignment limit: -0.3 mm (unchanged)
  • Upper alignment limit: 0.3 mm (unchanged)

Working through the calculation

  • Applying the documented formula (Alignment is inside spec when measured offset is between lower and upper limits) to the inputs above produces each figure below.
  • At this operating point the engine returns 0 outside for alignment inside spec, the number this scenario is built around.
  • At this operating point the engine returns -0.15 mm for nearest alignment margin.
  • At this operating point the engine returns 0 mm for lower alignment limit.
  • At this operating point the engine returns 0.3 mm for upper alignment limit.

How this compares with the baseline

  • Against the tool's baseline example, where measured stack alignment offset sits at 0.18 mm and the headline result is 1 inside, this scenario comes in 100% below the baseline at 0 outside.
  • It reports whether a measured stack alignment offset falls between the lower and upper tolerance limits and the distance from the measurement to the nearest limit. The value of this scenario is the size of the gap it exposes: that gap, priced out over a year, is the budget you can justify spending to close it.

Results at a glance

  • Alignment inside spec: 0 outside (headline result)
  • Nearest alignment margin: -0.15 mm
  • Lower alignment limit: 0 mm
  • Upper alignment limit: 0.3 mm

Run it with your numbers

  • Every input above is editable in the live Cell Stack Alignment Spec Window calculator, which recalculates instantly and can be shared with the inputs intact.

Last reviewed 2026-05-12.