# Automotive Ev Tools

> >

- **Type:** Skill
- **Install:** `agentstack add skill-pangzhenying2025-hermes-automotive-skills-automotive-ev-tools`
- **Verified:** Yes — security-reviewed for prompt injection and unsafe behavior
- **Seller:** [pangzhenying2025](https://agentstack.voostack.com/s/pangzhenying2025)
- **Installs:** 0
- **Category:** [Agent Skills](https://agentstack.voostack.com/c/agent-skills)
- **Latest version:** 0.1.0
- **License:** MIT
- **Upstream author:** [pangzhenying2025](https://github.com/pangzhenying2025)
- **Source:** https://github.com/pangzhenying2025/hermes-automotive-skills/tree/main/skills/automotive-ev-tools

## Install

```sh
agentstack add skill-pangzhenying2025-hermes-automotive-skills-automotive-ev-tools
```

Requires the [AgentStack CLI](https://agentstack.voostack.com/docs/cli). Works with Claude Code, Cursor, and any MCP-compatible agent.

## About

# Automotive Ev Tools

5 skill files covering ev-tools domain for automotive software engineering.

## Applicable Standards

- ASPICE Level 2/3 for software process
- ASPICE Level 3
- AUTOSAR 4.4
- AUTOSAR 4.4 for software architecture
- IEC 61851 EV charging systems
- IEC 63110 Management of EV charging infrastructure
- IPC-2221 PCB design standards
- ISO 12405 Lithium-ion battery testing
- ISO 15118 Vehicle-to-Grid communication
- ISO 26262
- ISO 26262 (for automotive variants)
- ISO 26262 ASIL-C/D for BMS safety functions
- ISO 6469-1 Electric safety
- ISO 6469-1 Electric vehicle safety
- OCPP 1.6J (JSON over WebSocket)
- OCPP 2.0.1 (ISO 15118 integration)
- SAE J2464 EV battery abuse testing
- UL 1973 Batteries for stationary applications
- UN ECE R100 Battery safety and crash testing
- UN ECE R100 Battery safety regulations
- USABC Battery Performance Goals
- VDA Battery System Standards

## Use Cases

- EV battery pack architecture design
- Cell selection and benchmarking
- Module and pack mechanical layout
- Thermal management system design
- BMS integration and wiring harness
- Safety analysis (FMEA, FTA, abuse testing)
- Weight and cost optimization
- Modular BMS PCB design and layout
- bq76940/ISL94202 AFE integration
- MPPT solar charging integration
- ThingSet protocol communication
- Load management and DC/DC control
- EV charge point software development
- Central system (CSMS) integration
- Smart charging and load management
- OCPP 1.6J and OCPP 2.0.1 protocol implementation
- Charging session management and billing
- Open-source BMS software architecture
- Cell monitoring and balancing algorithms
- SOC/SOH estimation implementation

## Topics Covered

### Battery Modeling

- pybamm-battery-modeling

### Bms Hardware

- libresolar-modular-bms

### Bms Software

- openbms-integration

### Charging Infrastructure

- ocpp-charging-protocol

### Pack Design

- battery-design-studio

## Constraints

- Backward compatibility with OCPP 1.6J for existing infrastructure
- Billing accuracy requirements (MID-certified meters)
- Certification costs for automotive production use
- Component availability for open-source BOM
- Computational performance for real-time model variants
- Cost target 0C before charge acceptance
- Cabin heat recovery to battery thermal loop

### Safety Analysis

- **FMEA (Failure Modes and Effects Analysis)**:
- Cell failures: Internal short, thermal runaway, venting
- BMS failures: Sensor faults, contactor weld, firmware bugs
- Thermal failures: Coolant leak, pump failure, blocked flow
- Mechanical failures: Module retention, connector loosening, vibration damage

- **FTA (Fault Tree Analysis)**:
- Top event: Thermal runaway propagation to full pack
- Contributing events: Cell defect + overcharge + cooling failure
- Mitigation: Firewall between modules, early fault detection, contactor trip

- **Abuse testing per SAE J2464**:
- Mechanical: Crush, nail penetration, drop
- Electrical: Overcharge, over-discharge, short-circuit
- Thermal: Oven exposure, thermal shock
- Pass criteria: No fire or explosion

- **Crash safety per UN ECE R100**:
- Frontal, side, rear, pole impact crash simulations
- HV interlock integrity, post-crash isolation verification
- Physical barriers to protect battery from intrusion

### Weight and Cost Optimization

- **Mass breakdown**:
- Cells: 60-70% of pack weight
- Module structure: 10-15%
- Pack enclosure: 10-15%
- BMS and wiring: 5-10%
- Thermal system: 5-10%

- **Cost breakdown** ($/kWh):
- Cells: 70-80% of pack cost
- Module assembly: 5-10%
- Pack integration: 5-10%
- BMS: 5-10%
- Thermal management: 3-5%

- **Optimization strategies**:
- Cell-to-pack (CTP) architecture: Eliminate modules, integrate cells directly
- Structural battery pack: Pack enclosure as load-bearing chassis component
- Standardized modules: Platform sharing across vehicle models
- Lightweighting: Aluminum vs steel, optimized ribbing, topology optimization

## Approach

1. **Concept phase**: Define pack energy/power, voltage, package space
2. **Cell benchmarking**: Test candidate cells for performance, safety, cost
3. **Preliminary design**: CAD layout of modules and pack, thermal simulation
4. **Detailed design**: Drawings for enclosure, busbar, coolant plate, BMS integration
5. **Prototype build**: Assemble alpha pack, install in test vehicle
6. **Validation testing**: Thermal, vibration, crash, abuse, durability
7. **Design refinement**: Iterate based on test results
8. **Production release**: Final drawings, BOM, assembly process, quality plan

## Deliverables

- Battery pack specification (energy, power, voltage, weight, cost, life)
- Cell selection report with benchmarking data
- CAD models (CATIA, SolidWorks) of module and pack
- Thermal simulation results (CFD, transient analysis)
- Electrical schematics (HV distribution, BMS wiring)
- Safety analysis (FMEA, FTA, abuse test reports)
- Bill of Materials (BOM) with cost estimate
- Manufacturing assembly instructions and test plan

## Best Practices

- **Design for manufacturing (DFM)**: Minimize manual assembly, automate welding
- **Design for serviceability (DFS)**: Module replacement without full pack disassembly
- **Design for recycling**: Material separation, labeled plastics, reusable structure
- **Concurrent engineering**: Involve BMS, thermal, safety teams early
- **Digital twin**: Build simulation model in parallel with physical pack
- **Benchmarking**: Teardown competitor packs (Tesla, GM, VW) for best practices

## Integration with Vehicle Development

- **Packaging**: Coordinate with vehicle design for underbody space, ground clearance
- **Electrical**: HV interlock loop, isolation monitoring, DC/DC converter
- **Thermal**: Integrate battery chiller with cabin HVAC system
- **Crash**: Collaborate with safety team on crash structures and intrusion barriers
- **Diagnostics**: CAN communication to instrument cluster for SOC/range display
- **Charging**: DC fast charge thermal constraints, preconditioning strategy

## Tools and Software

- **CAD**: CATIA V5/3DX, SolidWorks for mechanical design
- **CFD**: ANSYS Fluent, Star-CCM+ for thermal simulation
- **FEA**: ANSYS Mechanical, Abaqus for structural and crash analysis
- **Electrical**: AutoCAD Electrical, Zuken E3.series for schematics
- **Battery modeling**: MATLAB/Simulink, PyBaMM for electrochemical simulation
- **Cost modeling**: aPriori, Boothroyd Dewhurst DFM for cost estimation

### libresolar-modular-bms

## Core Competencies

Expert in LibreSolar modular open-source battery management system, covering hardware design, firmware development, and system integration for automotive EV and stationary energy storage.

### LibreSolar BMS Architecture

- **Modular topology**: Stackable boards for 3S to 15S per module, daisy-chained to 400S+
- **AFE chips**: TI bq76940 (5S), bq76930 (10S), bq76920 (15S), Renesas ISL94202
- **STM32 microcontroller**: STM32L452 or STM32G431 for low-power operation
- **Communication**: CAN, UART, I2C for multi-module systems
- **ThingSet protocol**: Standardized data model for battery parameters and control

### Hardware Design Features

- **PCB layout**:
- 4-layer board with dedicated analog ground plane
- Kelvin sensing for accurate cell voltage measurement
- High-current traces (50A+) with thermal reliefs
- Creepage/clearance per IEC 60664 for HV isolation

- **Cell monitoring**:
- Differential voltage measurement (mV accuracy)
- Balancing FETs (100 mA passive balancing per cell)
- Temperature sensing via NTC thermistors (8 channels)
- External current sensor interface (hall effect or shunt)

- **Protection circuits**:
- High-side and low-side MOSFET drivers for main contactors
- Pre-charge resistor circuit for capacitor inrush limiting
- Fuse or circuit breaker coordination
- Reverse polarity protection on all connectors

- **Power supply**:
- Isolated DC/DC converter for microcontroller power
- LDO regulators for AFE chip supply
- Battery voltage range: 12V to 800V pack support

### Firmware Features

- **State machine**: Idle -> Pre-charge -> Normal -> Fault handling
- **SOC estimation**: Coulomb counting with OCV calibration
- **Balancing logic**: Configurable thresholds and algorithms
- **MPPT charging**: Perturb & Observe algorithm for solar input
- **Load management**: DC/DC converter control, inverter enable/disable
- **Data logging**: Circular buffer with CAN/UART export
- **Configuration**: ThingSet commands for runtime parameter adjustment

### ThingSet Protocol

- **Data model**: Hierarchical structure for battery parameters
- `/battery/voltage`, `/battery/current`, `/battery/soc`
- `/cells/voltages`, `/cells/temperatures`
- `/config/limits/voltage_max`, `/config/limits/current_charge_max`

- **Transport layers**: CAN, UART, LoRaWAN for remote monitoring
- **Request/Response**: JSON-style commands for diagnostics
- **Pub/Sub**: Periodic broadcast of telemetry data

### MPPT Solar Charging

- **Algorithm**: Perturb & Observe with adaptive step size
- **Input voltage range**: 12V to 150V solar panel input
- **Efficiency**: >95% at rated power
- **CC-CV transition**: Constant current to constant voltage charging
- **Temperature compensation**: Adjust charge voltage by -3 mV/C/cell

### Load Management

- **DC/DC converters**: Buck/boost control for 12V/24V/48V loads
- **Inverter interface**: Enable signal based on SOC and load demand
- **Priority load shedding**: Disconnect non-critical loads at low SOC
- **Power limiting**: Reduce output power when battery temperature high

## Approach

1. **Hardware Selection**: Choose AFE chip based on cell count (bq76940 for 12S, ISL94202 for 15S)
2. **PCB Design**: Layout in KiCad with LibreSolar reference design as baseline
3. **BOM Sourcing**: Select automotive-grade components (AEC-Q100 for ICs, -40 to 125C rating)
4. **Firmware Porting**: Clone LibreSolar firmware repo, configure for hardware variant
5. **Calibration**: Measure voltage/current sensor gains and offsets
6. **Integration**: Connect to solar MPPT, DC/DC converter, CAN bus
7. **Validation**: Run charge/discharge cycles, verify protection triggers
8. **Enclosure Design**: IP65-rated housing for automotive/outdoor use

## Deliverables

- KiCad PCB design files (.kicad_pcb, .kicad_sch) with Gerbers
- Bill of Materials (BOM) with Mouser/Digikey part numbers
- Firmware source code (C/C++ for STM32) with build instructions
- ThingSet configuration files (.yaml) for data model
- Assembly instructions and test procedures
- Enclosure CAD files (.step) with mounting brackets
- Validation test report (charge/discharge, protection, temperature)

## Best Practices

- **Open-source licensing**: Hardware under CERN-OHL-P, firmware under Apache 2.0
- **Community engagement**: Contribute improvements back to LibreSolar GitHub
- **Modular design**: Keep modules under 15S for safety and repairability
- **Thermal management**: Heatsink for balancing FETs, airflow for high-current paths
- **EMC compliance**: Shielded CAN cables, ferrite beads, proper grounding
- **Safety testing**: Fault injection (over-voltage, over-current, short-circuit)
- **Documentation**: Schematic annotations, silkscreen labels, wiring diagrams

## Integration with Automotive EV Systems

- **CAN bus**: Broadcast SOC/SOH to VCU using J1939 or custom DBC
- **Charger interface**: Pilot signal (J1772, CCS) for AC/DC charging
- **Motor inverter**: Current limit and enable signal
- **Thermal system**: Request coolant pump when cell temp > 40C
- **Diagnostics**: UDS protocol access via CAN for service tools

## LibreSolar Ecosystem

- **LibreSolar Charge Controller**: MPPT solar charger with ThingSet
- **LibreSolar Data Manager**: Cloud-based monitoring dashboard
- **LibreSolar DC Nanogrid**: 48V DC distribution for off-grid systems
- **Community forums**: Active support on GitHub discussions and Discord

## Safety Considerations

- **Isolation monitoring**: Detect pack-to-chassis faults
- **Fusing strategy**: Per-module fuses for parallel strings
- **Thermal runaway detection**: dT/dt monitoring with alarm
- **Fail-safe shutdown**: Open contactors on firmware watchdog timeout
- **Field serviceability**: Modular replacement without full pack disassembly

### ocpp-charging-protocol

## Core Competencies

Expert in Open Charge Point Protocol (OCPP) implementation for electric vehicle charging infrastructure, covering charge point firmware, central system integration, and smart charging orchestration.

### OCPP Protocol Versions

- **OCPP 1.6J** (most widely deployed):
- JSON messages over WebSocket (secure wss:// or plain ws://)
- Core profile: Boot, heartbeat, authorize, start/stop transaction, meter values
- Smart charging profile: Charging profiles, composite schedules
- Reservation profile: Reserve charging connector
- Firmware management profile: Remote firmware updates

- **OCPP 2.0.1** (emerging standard):
- Enhanced security with ISO 15118 Plug & Charge
- Device model for advanced configuration
- Improved smart charging with detailed power schedules
- Display messages for driver interaction
- Tariff and cost information
- Data transfer extensions

### Charge Point Architecture

- **Hardware components**:
- Charging controller (STM32, NXP S32, Raspberry Pi)
- Power electronics (AC EVSE or DC fast charger)
- Energy meter (MID-certified for billing)
- RFID reader for user authentication
- Display and HMI (status LEDs, LCD/touchscreen)
- Connectivity (Ethernet, 4G LTE, WiFi)

- **Software stack**:
- OCPP client library (C++, Java, Python)
- WebSocket client with TLS/SSL
- Local authorization cache (RFID whitelist)
- Transaction logging and persistence
- Real-time clock and time synchronization (NTP)
- Watchdog and fault recovery

### OCPP Message Flow

- **Initialization**:
1. BootNotification: Charge point registers with CSMS
2. CSMS responds with Accepted/Pending/Rejected + heartbeat interval
3. GetConfiguration: CSMS retrieves charge point settings
4. ChangeConfiguration: CSMS sets parameters (e.g., MeterValueSampleInterval)

- **Authentication**:
1. Authorize: Send RFID tag ID to CSMS
2. CSMS checks user account status, responds with Accepted/Blocked/Invalid
3. Local authorization: If offline, check cached ID list

- **Charging session**:
1. StartTransaction: Report connector ID, RFID tag, meter start value, timestamp
2. CSMS responds with transaction ID
3. MeterValues: Periodic energy/power measurements during charging
4. StopTransaction: Report meter stop value, stop reason, transaction data
5. CSMS responds with acknowledgment

- **Smart charging**:
1. SetChargingProfile: CSMS sends power limit schedule (kW vs time)
2. Charge point applies composite schedule from all active profiles
3. GetCompositeSchedule: Query effective charging limit
4. ClearChargingProfile: Remove expired or superseded profiles

- **Firmware management**:
1. UpdateFirmware: CSMS provides firmware URL and install time
2. Charge point downloads firmware, verifies checksum
3. FirmwareStatusNotification: Downloaded -> Installing -> Installed
4. Reboot and resume operation

### Central System (CSMS) Integration

- **Backend architecture**:
- WebSocket server farm (Node.js, Spring Boot, Go)
- Database: PostgreSQL for transactions, MongoDB for device state
- Message queue: RabbitMQ or Kafka for async processing
- Load balancer: NGINX or AWS ALB for charge point connections
- Cache: Redis for session state and authorization lists

- **Business logic**:
- User management: Accounts, RFID cards, payment methods
- Tariff engine: Time-of-use pricing, demand charges, subscription plans
- Load management: Distribute available power across charge points
- Reporting: Energy delivered, utilization, revenue analytics
- Notifications: SMS/email for session start/stop, faults

- **Third-party integrations**:
- Payment gateways: Stripe, PayPal, credit card processing
- Roaming networks: Hubject, Gireve for cross-operator access
- Fleet management: API for fleet operator dashboards
- Grid operators: De

…

## Source & license

This open-source skill is cataloged on AgentStack and links to its original source — we do not rehost the code.

- **Author:** [pangzhenying2025](https://github.com/pangzhenying2025)
- **Source:** [pangzhenying2025/hermes-automotive-skills](https://github.com/pangzhenying2025/hermes-automotive-skills)
- **License:** MIT

Install and usage instructions live in the source repository linked above.

## Pricing

- **Free** — Free

## Security capabilities

Automated source analysis of v0.1.0 — what this tool can access:

- **Network access:** yes
- **Filesystem access:** no
- **Shell / process execution:** no
- **Environment & secrets:** no
- **Dynamic code execution:** no

*"Yes" means the capability is present in the source — more access means more to trust, not that it is unsafe.*


## Versions

- **0.1.0** — security scan: passed — Imported from the upstream source.

## Links

- Listing page: https://agentstack.voostack.com/l/skill-pangzhenying2025-hermes-automotive-skills-automotive-ev-tools
- Seller: https://agentstack.voostack.com/s/pangzhenying2025
- Browse the marketplace: https://agentstack.voostack.com/browse

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