Need a Pre-Flight Check for Your EV Pack, Before You Twist the Throttle?

If you’re building or upgrading an electric motorcycle or e-moto, you’ve probably had that moment:

“Will this battery actually survive the way I want to ride… or am I one bad pull away from a BMS cutoff, cooked wires, or worse?”

That’s exactly why I built the EV Battery Compatibility Calculator_01 for 10FoldMoto.

This isn’t just a “plug in volts and amps, get a range number” toy. It’s a chemistry-aware, resistance-based, risk-mapping tool designed to sanity-check your battery pack before you dump thousands of watts through it in the real world.

Why I Built This Calculator

Most online EV calculators stop at:

• Pack voltage

• Capacity in Ah

• Maybe a rough range estimate

But if you’ve ever pushed a SurRon, Talaria, DIY e-moto, or custom pack hard, you know the real questions are:

• How much will my pack sag under load?

• Will my BMS cut out when I pin it at a low State of Charge?

• Are my wires and connectors actually safe at my target amps?

• How hot will this pack get if I ride it the way I actually ride?

• Is there any early warning of thermal runaway or fire risk?

The EV Battery Compatibility Calculator_01 (Phase_02) tries to answer those questions in one place, on one screen, using standard electrical formulas, realistic cell profiles, and simple thermal modeling.

Think of it as a pre-flight checklist for volts, amps, and heat.

Our Online Calculator vs Other Online Calculators.

Our Online Calculator Vs Lab Grade Testing.

A Quick Tour of the Calculator

The UI is styled like a The Designers Republic / Virgil Abloh-inspired HUD, featuring bold labels, modular cards, and a clean dark/light/transparent theme switcher, allowing you to read it comfortably in any environment.

At the top, the header tells you:

• Tool ID: EV_Battery_Compatibility_Calculator_01

• Phase: PHASE_02 – the current development stage

• Chemistry focus: NMC, NCA, LiPo, LiFePO4 support

• Disclaimer: it’s math-accurate, but not a replacement for real-world testing or certification

Below that, the calculator walks you through everything that actually matters for a hard-ridden EV pack.

Step 1: Build Your Pack Model

In the INPUT / PACK MODEL section, you define your battery as you would on a whiteboard:

• Build Name – e.g. 72V 60Ah SurRon

• Battery Type – Li-ion, LiPo, LiFePO4

• Battery Cell Model (Optional)

  • Samsung 40T

  • Molicel P42A

  • Sony VTC6

  • Or a fully custom setup

When you choose a known cell, the calculator can auto-fill:

• Cell resistance

• Cell capacity (Ah)

• C-rating

• Pack nominal and full voltage (based on S count)

From there, you layer in the real-world details:

• Ambient temperature (°C) – because cold packs sag harder

• Internal resistance per cell (Ω)

• Max cell imbalance (V) – to model worst-case weak cells

• Series (S) and Parallel (P) layout

• C-rating, charger current/voltage, pack capacity (Ah)

• Continuous & peak discharge current (A)

• Continuous & peak power (W)

• Peak duration (seconds)

You can enter:

• Current battery voltage (V) or

• Current State of Charge (SoC %)

The calculator uses chemistry-specific OCV curves to estimate SoC from pack voltage if you don’t enter SoC manually. If you do enter SoC, your value wins.

Step 2: Wire, Connectors, and Thermal Mass

The calculator doesn’t stop at the cells. It also models the full DC path between battery and controller:

• Wire gauge (AWG 2–24)

• Round-trip wire length (meters)

• Connector type – QS8, QS10, QS12 with typical milliohm values

From that, it calculates:

• Wire resistance (temperature-corrected for copper)

• Connector resistance

• Total system resistance = cells + wires + connector

For thermal modeling, you also enter:

• Battery weight (kg)

• Battery specific heat (J/kg°C) – often around 900 for lithium cells

• Battery enclosure thermal resistance (°C/W)

• Battery age (full cycles)

This lets the calculator estimate:

• Thermal mass

• Heat rise under continuous and peak load

• Resistance growth with aging (more cycles = more internal resistance)

Step 3: Range, Ride Style, and Real-World Use

Energy without context is just a number, so there’s a section for average energy consumption (Wh/km) with presets:

• Street: 30 Wh/km

• Off-road: 60 Wh/km

• Race: 90 Wh/km

From there, the calculator estimates:

• Total pack energy (Wh)

• Full-charge range (km)

• Remaining range based on SoC

You also get continuous and peak horsepower from your power entries, so you can translate watts into something your motorcycle brain recognizes.

What the Calculator Actually Outputs

When you hit Calculate, the results card turns into a modular risk dashboard:

1. System Verdict

A top-level verdict such as:

• ✅ “Looks good for typical riding. No major electrical or thermal red flags.”

• ⚠️ “Borderline setup. Pay attention to sag, heat, and cell balance.”

• 🚫 “Not recommended to ride as-is. Critical risks detected.”

Alongside that, you see:

• Estimated SoC (manual or curve-based)

• Continuous sag (%)

• Peak sag (%)

• Overall risk state – visualized via a chip and a risk bar

2. Battery Risk Map

A dedicated module breaks down:

• Thermal runaway risk – based on heat per kg at peak load

• Fire risk warnings – normal, high heat, or dangerous

• Fast charging warnings – C-rate vs capacity

• Enclosure temperature rise (°C)

• Imbalance and worst-cell behavior under peak sag

• Over-voltage / over-charge risk

• Cutoff risk – whether the peak load will drop cells below the cutoff

You get simple human language like:

• ✅ “No thermal risk detected.”

• ⚠️ “High heat load. Cells may experience stress—monitor closely.”

• 🔥 “Danger zone: pre-runaway conditions possible.”

• 🚨 “Thermal runaway likely! Shut down immediately.”

3. Pack Electrical Spec

For the nerds (hi, that’s us):

• Adjusted cell resistance (with SoC, temperature, and aging factored in)

• Raw internal resistance

• Temperature-corrected wire resistance vs raw

• Connector resistance

• System resistance

• Continuous and peak voltage drop and sag percentages

4. Performance & Range

This module covers:

• Pack energy at nominal voltage (Wh)

• Energy used during a configured peak burst (Wh)

• Full-charge range estimate (km)

• Remaining range at your current SoC

• Wh/kg

• Continuous & peak horsepower

• Estimated system efficiency (%), based on power vs losses

5. BMS / Charging / Sag

Finally, the BMS brain and safety bits:

• BMS temperature cutoff window (if supplied)

• Balance current & passive bleed rate

• Peak draw and whether it’s “safe burst” or “too much.”

• C-rating vs continuous current

• Wire gauge vs safe current (will this cook your cables?)

• Estimated charge time (hours)

• Per-cell idle and peak-load voltage

• Max theoretical power from C-rating

• Overall sag status and risk level

What This Calculator Doesn’t Do (Yet)

This tool is powerful, but it’s still Phase_02 and intentionally focused on the battery and DC side. It does not:

• Simulate full drive cycles with hills, regen, traffic, or race telemetry

• Model motor phase current, FOC tuning, torque curves, or field-weakening

• Calculate the exact 0–60 times or top speed (that will live in the future motor/controller/gearing module)

• Replace detailed lab-grade HPPC testing or OEM battery validation

• Offer internal cell-level temperature mapping or coolant loop simulations

• Emulate full BMS firmware logic with exact fault timers and derates

• Provide legal or standards certification of any kind

It’s a sanity filter and design tool, not a certification stamp.

Who This Calculator Is For

If any of these sound like you, this tool was built for you:

• You’re building or upgrading an electric dirt bike, SurRon, Talaria, or DIY e-moto

• You have (or want) a high-power pack and want to know if your battery, wiring, and connectors are actually safe at your target amps

• You’ve hit BMS cutoff before and never want that surprise again mid-wheelie

• You care about thermal runaway risk, not just stats on a spec sheet

• You like tools that feel more like pro lab gear than a toy calculator

Try the EV Battery Compatibility Calculator

If you’re planning a new pack, stress-testing an existing one, or just want to know what’s really happening under the plastics, the EV_Battery_Compatibility_Calculator_01 gives you a clear, honest look at:

• Voltage sag

• Heat buildup

• Wire and connector safety

• BMS risk

• Range and performance reality

Use it as a pre-flight checklist before you commit money, time, and trust to a battery build.

You can try the calculator here:

EV Battery Compatibility Calculator by 10FoldMoto

Design smarter, Ride hard! ⚡🏁