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Electric Delivery Van Battery Degradation Calculator

This calculator estimates how much usable battery capacity an electric delivery van may retain after a specified period of service. It combines calendar aging with cycle-related wear based on annual mileage, energy consumption, battery size, and an assumed degradation rate per equivalent full cycle.

Fleet operators can use the estimate to compare replacement timing, range resilience, and charging strategy before committing a van to demanding routes. The result is a planning estimate rather than a battery health diagnosis; actual degradation depends on cell chemistry, temperature, charging speed, depth of discharge, and the vehicle's battery-management system.

Calculator inputs

kWh
mi/yr
kWh/mi
years
%/yr
%/cycle
Result
—
Estimated retained battery capacity
Capacity retained—
Capacity lost—
Equivalent full cycles—
Estimated range at end—

1. Enter the original pack size
Use the vehicle’s usable battery capacity when available, not the gross cell capacity.

2. Add annual route distance
Enter the miles the van is expected to travel in a typical operating year.

3. Set energy consumption
Use a route-specific kWh-per-mile figure that includes payload and climate conditions.

4. Choose the service period
Enter the number of years you want to project.

5. Apply degradation assumptions
Use calendar and cycle rates suitable for the battery chemistry and charging pattern.

6. Review remaining capacity
Compare retained kWh, capacity loss, cycle count, and end-of-period range.

Retained capacity = Original capacity × (1 − Total degradation ÷ 100)

Total degradation (%) = Calendar rate × Years + Cycle rate × Equivalent full cycles

Equivalent full cycles = Annual miles × Energy use × Years ÷ Original battery capacity

What the result means

The main result is the estimated usable battery capacity remaining at the end of the selected service period.

The model adds calendar and cycle degradation linearly and caps total loss at 100%. Real battery aging is usually nonlinear.

Given: 90 kWh battery, 30,000 miles per year, 0.42 kWh per mile, 5 years, 1.5% annual calendar loss, and 0.025% per equivalent full cycle.

Calculation: Cycles = 30,000 × 0.42 × 5 ÷ 90 = 700. Total degradation = 1.5 × 5 + 0.025 × 700 = 25%. Retained capacity = 90 × 0.75 = 67.5 kWh.

Result: About 67.5 kWh remains, or 75% of original capacity. At 0.42 kWh per mile, that supports an estimated 161 miles before reserve margins.

What is an equivalent full cycle?

It is cumulative battery throughput equal to one complete charge and discharge of the original usable capacity. Several partial cycles can add up to one equivalent full cycle.

Should I use gross or usable battery capacity?

Use usable capacity whenever possible because that is the energy available to operate the van. Using gross capacity can overstate range and understate cycle count.

Does fast charging increase degradation?

Frequent high-power charging can increase heat and stress, but the effect varies by pack design and thermal management. Adjust the degradation assumptions if the duty cycle relies heavily on rapid charging.

Why can actual battery health differ from this result?

Temperature, state-of-charge habits, depth of discharge, cell chemistry, and software limits all affect aging. This calculator is a scenario model, not a battery test.

How can this estimate support fleet planning?

Use retained capacity to test whether older vans can still complete assigned routes with an operational reserve. It can also help compare battery replacement, route reassignment, and vehicle renewal options.