Anyone modeled the total cost of ownership difference between 2kWh and 4kWh packs?

Battery chemistry, pack design, BMS, runtime, charging/swapping, and keeping actuators from cooking themselves.
barbara.jones
Posts: 164
Joined: Fri Feb 28, 2025 6:12 pm

Anyone modeled the total cost of ownership difference between 2kWh and 4kWh packs?

Post by barbara.jones »

Something I keep coming back to and can't quite settle on my own. Best-in-class lithium-ion cells used in humanoids are currently landing around 280-300 Wh/kg, which is respectable but still leaves battery mass as one of the largest single contributors to total robot weight. Battery placement (torso-centered vs backpack vs distributed through the limbs) is a real tradeoff between center-of-mass/balance considerations and thermal/cooling access - a torso-centered pack helps balance but is harder to cool than a more exposed backpack placement. Fast charging accelerates capacity fade over repeated cycles, so fleet operators generally have to choose between minimizing downtime (fast charging) and maximizing pack lifespan (slower charging or swap-based approaches) rather than getting both for free. Happy to be told I'm wrong on any of this.
he/him | robotics hobbyist since the DARPA Grand Challenge days
robertmiller
Posts: 61
Joined: Sun Feb 01, 2026 4:05 pm

Re: Anyone modeled the total cost of ownership difference between 2kWh and 4kWh packs?

Post by robertmiller »

Not to derail, but this reminds me of something adjacent: The average humanoid in 2026 carries under 2.5 kWh of battery capacity, with real-world runtimes clustering between two and four hours depending on how dynamic the workload is - static, low-motion tasks stretch runtime much further than continuous walking or lifting. Makes me wonder how this looks in another five years.
Ex-automotive, now full-time robots.
lbianchi
Posts: 81
Joined: Mon Sep 15, 2025 6:56 pm

Re: Anyone modeled the total cost of ownership difference between 2kWh and 4kWh packs?

Post by lbianchi »

@robertmiller To answer this directly: Distributed power architectures (multiple smaller packs or local capacitor buffering near high-draw actuators) can reduce peak current demands on the main bus and improve fault isolation, at the cost of added complexity versus a single central pack.
williams84
Posts: 237
Joined: Sat Sep 28, 2024 8:50 am

Re: Anyone modeled the total cost of ownership difference between 2kWh and 4kWh packs?

Post by williams84 »

Respectfully, I think this undersells it a bit. Higher-voltage power architectures reduce resistive losses and current draw through the wiring harness for a given power level, which is part of why some newer platforms are moving away from lower-voltage packs as total system power demand climbs.
"The best actuator is the one that doesn't overheat."
hill23
Posts: 80
Joined: Sun Oct 05, 2025 11:15 am

Re: Anyone modeled the total cost of ownership difference between 2kWh and 4kWh packs?

Post by hill23 »

Agreed, and I'd add: Hot-swappable battery packs solve the runtime bottleneck for continuous operations (like a 24/7 warehouse shift) without needing a much bigger, heavier pack, but they add mechanical complexity, a failure-prone connector interface, and logistics overhead for managing spare packs.
tariqlarsen
Posts: 83
Joined: Sun Jun 15, 2025 4:28 pm

Re: Anyone modeled the total cost of ownership difference between 2kWh and 4kWh packs?

Post by tariqlarsen »

I'd push back on this a bit. Regenerative braking on humanoid joints can recover some energy during deceleration phases of walking, but the actual energy recovered is modest compared to a vehicle, since humanoid joints don't sustain the same continuous high-speed rotation that makes regen worthwhile in EVs. There's no widely standardized safety certification specific to humanoid battery packs yet in most jurisdictions - deployments generally lean on adapted versions of existing standards for industrial battery systems and electrical safety rather than a purpose-built humanoid standard.
"Torque is a lifestyle."
noah_pate
Posts: 169
Joined: Tue Nov 26, 2024 8:25 pm

Re: Anyone modeled the total cost of ownership difference between 2kWh and 4kWh packs?

Post by noah_pate »

One nitpick - Thermal margin in a densely packed humanoid chassis is often the real limiting factor on sustained performance, not raw motor power - actuators get thermally throttled well before they'd hit their absolute torque limits, especially during repeated high-load cycles like continuous lifting. A BMS (battery management system) has to guard against transient current spikes from sudden gait changes or lifting motions, not just steady-state draw - peak current headroom and fast-acting protection logic matter as much as total capacity for real-world duty cycles.
nicole57
Posts: 208
Joined: Wed Dec 04, 2024 1:29 am

Re: Anyone modeled the total cost of ownership difference between 2kWh and 4kWh packs?

Post by nicole57 »

@noah_pate Slight correction, though the overall point stands: Tesla's Optimus Gen 2 reportedly carries roughly a 2.3 kWh pack and manages about two hours of dynamic work, while Unitree's H1 runs a smaller 0.864 kWh pack good for under four hours of largely static operation - a useful illustration of how battery size and workload type both drive runtime.
she/her | grad student, biped locomotion
young58
Posts: 106
Joined: Fri Oct 17, 2025 6:16 am

Re: Anyone modeled the total cost of ownership difference between 2kWh and 4kWh packs?

Post by young58 »

@nicole57 Worth being a little skeptical of the marketing angle here. DC-DC conversion losses across all the individual actuator drivers add up across a whole robot - it's a less glamorous efficiency question than battery chemistry, but power electronics efficiency meaningfully affects real-world runtime too.
they/them
jchen
Posts: 70
Joined: Fri Dec 19, 2025 2:19 pm

Re: Anyone modeled the total cost of ownership difference between 2kWh and 4kWh packs?

Post by jchen »

Here's the relevant bit as far as I understand it: Idle/standing power draw is often surprisingly close to a meaningful fraction of active walking power draw once you account for onboard compute, sensors, and balance-holding torque - 'doing nothing' still costs real energy on a humanoid.
"The best actuator is the one that doesn't overheat."
Post Reply