EV & Battery Manufacturing worked example

Cell Stack Alignment Spec Window with measured stack alignment offset of 0.09 mm: a worked example

Suppose measured stack alignment offset falls to 0.09 mm. This page works the full calculation at that level so you can see exactly which result moves and by how much. Check whether measured cell stack alignment is inside lower and upper alignment limits.

The inputs for this scenario

  • Measured stack alignment offset: 0.09 mm (the input this scenario stresses; the baseline uses 0.18)
  • Lower alignment limit: -0.3 mm (held at the documented default)
  • Upper alignment limit: 0.3 mm (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Alignment is inside spec when measured offset is between lower and upper limits.
  • Alignment inside spec works out to 1 inside at these inputs, and this is the headline figure for the scenario.
  • Nearest alignment margin works out to 0.09 mm at these inputs.
  • Lower alignment limit works out to 0 mm at these inputs.
  • Upper alignment limit works out to 0.3 mm at these inputs.

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 lands almost exactly on the baseline at 1 inside.
  • 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. When the numbers land here, the stressed input is the lever to work; the walkthrough above shows exactly how much each output recovers as it climbs back toward the baseline.

Results at a glance

  • Alignment inside spec: 1 inside (headline result)
  • Nearest alignment margin: 0.09 mm
  • Lower alignment limit: 0 mm
  • Upper alignment limit: 0.3 mm

Run it with your numbers

  • To rerun this with your own numbers, open the live Cell Stack Alignment Spec Window calculator, set measured stack alignment offset to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.