But on to a more fundamental question: what does 100% charge mean and how does the car determine when it has been reached? The obvious answer is that it has 100 kWh in it. But how do you know it has 100kWh it it? The only way to find out is to discharge it fully and I guess that's what this "battery calibration" that I see talked about here (but not in anything I've seen from Tesla) is about.
All good questions. A few points*:
First, generally, 100% is when the first call group reaches the pre-determined maximum cell-group voltage. Anything more is overcharging that cell group. Zero percent is the pre-determined safe minimum voltage.
Balancing is bringing all cell-groups to the exact same voltage level. It can happen anywhere, but TOC is the easiest because the top is the top and that is the maximum capacity of the pack. Just FYI.
Battery capacity in kWHrs is “best” determined by fully discharging the pack (to the lowest cell-group voltage) and then fully charging to 100% (as determined by above) while measuring current and voltage going in over time (voltage x current x time = killowatt-hours). Mostly, it’s tracked by starting somewhere and measuring the energy in and out and keeping track. This is why periodic charging to 100% is not a bad idea.
Final note: it’s is very difficult to know the “true” capacity of a pack (no matter which definition you are using). The usable energy out of a pack varies by discharge rate, temperature, where it is measured (because of losses along the way), etc.
VOLTAGE levels are the unchanging parameters used to determine safe charge and discharge levels, with no guard-banded buffer zone. In general, capacity is the energy obtained from a pack from Top Of Charge (TOC) to Bottom Of Charge (BOC) at the C-rate of the cell-group design for a given pack. If a cell group is designed to be discharged from full to empty at 10 amps (example) in one hour, the C-rate at 1C is 10 amps. 2C is 20 amps, etc.
Remember that all cell-groups inherently have slightly different capacities from each other to a tolerance know only to the manufacturer. A pack is only as good as its lowest capacity cell-group.
Voltage changes with pack charge level and a pre-determined plot of that vs. capacity from testing is used to determine remaining pack capacity.
*Blah blah blah temperature changes, algorithms, overhead, safety capacity, buffer zones, degradation, tolerances, internal resistance, consumer and designations, rated vs. actual, blah blah disclaimers on everything.
Whew!