Requirements

Battery System Requirements Checklist

Structured checklist covering electrical, physical, environmental, safety, and lifecycle requirements with verification traceability.

Last updated: 2026-01-15HTML Template

Battery System Requirements Checklist for Aerospace Applications

This battery system requirements checklist provides a structured framework for capturing and organizing requirements across all critical domains: electrical performance, physical constraints, environmental exposure, safety requirements, and lifecycle expectations. The checklist ensures completeness and traceability while enabling systematic verification planning for aerospace battery system design projects.

Unlike narrative requirements documents, this checklist format facilitates rapid gap analysis during requirements elicitation workshops and serves as a verification readiness assessment tool. Each checklist item maps to verification methods (analysis, inspection, demonstration, test) and acceptance criteria categories.

Application Context: From Requirements to Prototype to Production Battery Pack

Program Phase

Requirements capture and definition phase, typically early in concept development or prior to RFP response. This checklist supports the entire prototype to production battery pack lifecycle. Used during initial customer engagements to structure requirements discussions and identify gaps or ambiguities.

Decisions Supported

  • Feasibility assessment (can requirements be met with existing technology)
  • Architecture selection (voltage band, cooling approach, cell chemistry)
  • Development timeline estimation (complexity and risk drivers)
  • Cost and schedule implications of requirement tradeoffs
  • Verification approach and test planning scope

Input Requirements

Prerequisites

Mission profile and operational scenarios defined
Platform interfaces characterized (electrical, mechanical, thermal)
Applicable safety standards identified or regulatory requirements known
Stakeholders available for requirements clarification
Program timeline and quantity expectations established

Assumptions & Constraints

  • Assumes: Requirements capture session facilitated by engineer with battery systems experience
  • Assumes: Customer can provide or reference platform environmental specifications
  • Constraint: Checklist captures requirements, not design solutions or implementation details
  • Constraint: Specific acceptance criteria values will be coordinated based on application and test capabilities

Output Components

1. Electrical Requirements Section

  • Nominal voltage and voltage range (Vmin, Vmax)
  • Usable energy capacity (kWh)
  • Continuous power and peak power (kW, duration)
  • Charge rate requirements (if applicable)
  • Load profile characteristics (constant, pulsed, regenerative)
  • Efficiency targets

2. Physical Requirements Section

  • Maximum envelope dimensions (L × W × H)
  • Maximum mass
  • Mounting interface specifications
  • Center of gravity constraints (if applicable)
  • Connector locations and accessibility requirements

3. Environmental Requirements Section

  • Operating temperature range
  • Storage temperature range
  • Altitude exposure (pressure range)
  • Vibration profile (reference standard or frequency/amplitude)
  • Shock levels
  • Humidity and condensation exposure
  • Ingress protection rating (IP rating)

4. Safety & Protection Requirements Section

  • Safety interlock requirements (HVIL, E-stop)
  • Fault detection and isolation requirements
  • Protection thresholds (overvoltage, undervoltage, overcurrent, overtemperature)
  • Isolation resistance requirements
  • Fail-safe behavior definitions
  • Applicable safety standards

5. Interface Requirements Section

  • Electrical interface (connector type, pin assignments)
  • Mechanical interface (mounting pattern, thermal interfaces)
  • Thermal interface (coolant type, flow rate, inlet/outlet locations)
  • Communication interface (protocol, message structure, update rates)

6. Lifecycle & Performance Section

  • Cycle life expectation (cycles to X% capacity retention)
  • Calendar life expectation (years to Y% retention)
  • State estimation accuracy requirements (SOC, SOH)
  • Response time for power transients
  • End-of-life criteria

7. Verification Approach Section

  • Verification method mapping (analysis, inspection, demo, test)
  • Test environment requirements
  • Acceptance criteria categories for each requirement
  • Traceability matrix structure

Common Pitfalls

Pitfall: Conflating Requirements with Design Solutions

Issue: Checklist filled with implementation details (cell type, BMS architecture, specific components) rather than performance requirements and constraints.

Mitigation: Focus on "what" the system must achieve, not "how" it will be implemented. Requirements specify outcomes and boundaries; design specifies solutions. Review each checklist item and ask: "Does this constrain the outcome or prescribe the implementation?"

Pitfall: Incomplete Interface Definition

Issue: Electrical performance captured but connector type, communication protocol, or thermal interface left vague until late in design, causing integration delays.

Mitigation: Treat interface requirements with same rigor as performance requirements. Document connector part numbers (or acceptable equivalents), communication protocol versions, thermal interface materials and tolerances. Flag interfaces that are TBD and establish timeline for resolution.

Pitfall: Ambiguous Environmental Requirements

Issue: Environmental requirements stated qualitatively ("harsh environment," "aerospace conditions") without reference to quantitative test standards or platform specifications.

Mitigation: Reference platform environmental specifications or published standards (MIL-STD-810, DO-160). If platform specs are unavailable, state "environmental requirements to match platform exposure per [document reference] or to be coordinated." Avoid inventing test levels.

Pitfall: Missing Traceability Structure

Issue: Requirements captured but no unique identifiers assigned, making verification traceability and change management difficult.

Mitigation: Assign unique requirement IDs during initial capture using structured format (BATT-ELEC-001, BATT-MECH-005). Create traceability matrix placeholder linking requirements to verification methods. Establish change control process before requirements baseline.

Requirements Checklist Template

# BATTERY SYSTEM REQUIREMENTS CHECKLIST

## Project Information
Project Name: ___________________________________
Date: ___________  Version: _____  Author: ___________

## 1. ELECTRICAL REQUIREMENTS

□ Nominal voltage: _______ V
□ Operating voltage range: _______ V (min) to _______ V (max)
□ Usable energy capacity: _______ kWh
□ Continuous power: _______ kW
□ Peak power: _______ kW for _______ seconds/minutes
□ Charge rate: _______ C-rate or _______ kW (if applicable)
□ Load profile type: □ Constant power  □ Pulsed  □ Regenerative
□ Efficiency target: _______% (discharge or round-trip)
□ Verification method: □ Analysis  □ Test  □ Demonstration

## 2. PHYSICAL REQUIREMENTS

□ Maximum dimensions: _____ mm (L) × _____ mm (W) × _____ mm (H)
□ Maximum mass: _______ kg
□ Mounting interface: ______________________________
□ Center of gravity location: _______ (if critical)
□ Connector locations: _____________________________
□ Accessibility requirements: _______________________
□ Verification method: □ Inspection  □ Analysis  □ Test

## 3. ENVIRONMENTAL REQUIREMENTS

□ Operating temperature range: _____ °C to _____ °C
□ Storage temperature range: _____ °C to _____ °C
□ Altitude (pressure) range: _______ to _______ ft or kPa
□ Vibration profile: □ Reference: ____________  □ Custom: ___________
□ Shock levels: _______ G, _______ ms duration
□ Humidity exposure: _______ %RH, _______ °C
□ Ingress protection: IP _____ (dust/water)
□ EMC requirements: _______________________________
□ Verification method: □ Test per standard  □ Analysis

## 4. SAFETY & PROTECTION REQUIREMENTS

□ Safety interlock: □ HVIL required  □ E-stop response: _____ ms
□ Fault detection: □ Overvoltage  □ Undervoltage  □ Overcurrent  □ Overtemp
□ Protection thresholds: (specify as % or "to be coordinated")
  - Overvoltage: _______
  - Undervoltage: _______
  - Overcurrent: _______
  - Overtemperature: _______
□ Isolation resistance: _______ MΩ minimum
□ Fail-safe behavior: _______________________________
□ Applicable standards: □ IEC 62619  □ UL 2271  □ SAE J2464  □ Other: _______
□ Verification method: □ Test  □ Analysis  □ Inspection

## 5. INTERFACE REQUIREMENTS

Electrical Interface:
□ Connector type: _______________________________
□ Pin assignments: _______________________________
□ Mating connector: _______________________________

Mechanical Interface:
□ Mounting pattern: _______________________________
□ Thermal interface material: _______________________

Thermal Interface (if applicable):
□ Coolant type: _______________________________
□ Flow rate: _______ L/min
□ Inlet temperature: _______ °C
□ Inlet/outlet locations: _______________________

Communication Interface:
□ Protocol: □ CAN  □ CAN FD  □ Modbus  □ Other: _______
□ Baud rate: _______
□ Message structure: Reference ICD or specify: _____________
□ Update rate: _______ Hz
□ Verification method: □ Inspection  □ Test

## 6. LIFECYCLE & PERFORMANCE REQUIREMENTS

□ Cycle life: _______ cycles to _______% capacity retention
□ Calendar life: _______ years to _______% capacity retention
□ SOC estimation accuracy: ± _______%
□ SOH estimation accuracy: ± _______%
□ Power response time: _______ ms for step change
□ End-of-life criteria: _______________________________
□ Verification method: □ Test  □ Analysis  □ Demonstration

## 7. VERIFICATION APPROACH

Requirements Verification Matrix:
□ All requirements assigned unique IDs (format: BATT-XXX-###)
□ Verification method identified for each requirement
□ Test procedures identified or TBD flagged
□ Acceptance criteria defined (quantitative or category)
□ Traceability to design and test documented

Test Environment Needed:
□ Thermal chamber: _____ °C to _____ °C
□ Vibration table: _____ Hz, _____ G capability
□ Altitude chamber: _____ ft capability
□ Other: _______________________________

## 8. DOCUMENTATION DELIVERABLES

Customer requires:
□ Requirements specification document
□ Interface Control Document (ICD)
□ Design documentation (drawings, schematics, BOM)
□ Test plan and test procedures
□ Test reports (qualification, acceptance)
□ User/integration manual
□ Safety warnings and handling procedures
□ Other: _______________________________

## 9. ASSUMPTIONS & CONSTRAINTS

Document key assumptions:
- _________________________________________________
- _________________________________________________
- _________________________________________________

Document constraints:
- _________________________________________________
- _________________________________________________
- _________________________________________________

## 10. OPEN ITEMS / TBD

Item                                    | Owner      | Target Date
---------------------------------------|------------|-------------
                                       |            |
                                       |            |
                                       |            |

## APPROVAL

Requirements reviewed and approved by:

Customer: ____________________  Date: __________
EVolve Engineering: __________  Date: __________

Notes:
_________________________________________________________
_________________________________________________________
_________________________________________________________

Usage Note: This checklist is a starting point for requirements capture. Customize sections based on application domain (UAV, UUV, industrial, aerospace). Some items may not apply to all projects. Add domain-specific requirements as needed.

Related Resources

Article Information

Reviewed By

Justin Dunn

Founder & CEO

Last Updated

January 15, 2026

Sources & Standards Referenced

No external sources listed. This content is based on engineering principles and EVolve's design experience.

Sources Referenced

No external sources listed. This template structure is based on EVolve's internal requirements capture methodology.

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