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Skill Overview

From Cell to Pack; a one-day technical training programme that provides a concise yet comprehensive overview of battery production, from cell fundamentals to full pack integration. Aimed at professionals across energy storage and electrification sectors, the course explores how batteries work, the principles of charging and discharging, internal resistance, and State of Health (SoH). It also addresses pack structure, thermal management, electrical connections, and safety considerations, including hazards associated with high voltages. The session includes mobile-based quizzes and real-world case studies to reinforce learning. By the end of the course, participants will be equipped with practical insight into battery assembly processes, performance optimisation, and safe manufacturing practices.

Learning Objectives

1.	Explain the basic principles of electrochemistry and redox reactions relevant to battery technology.
2.	Describe the structure and function of battery cells, including anodes, cathodes, electrolytes, separators, and terminals.
3.	Define and interpret key performance indicators such as State of Charge (SoC), State of Health (SoH), internal resistance, and impedance.
4.	Understand the processes of charging and discharging, including current/voltage methods, lithium-ion movement, and the role of C-rates.
5.	Outline the cell-to-pack hierarchy, including series/parallel configurations, cooling systems, busbars, structural elements, and pack architecture.
6.	Describe the purpose and function of a Battery Management System (BMS) in monitoring and controlling battery performance and safety.
7.	Apply knowledge of insulation, isolation, and IP rating standards in the context of EV battery systems.
8.	Demonstrate awareness of safe working practices around hazardous voltages, including team-based procedures and risk mitigation strategies.
9.	Identify best practices for welding dissimilar metals and establishing effective electrical connections to ensure safety and performance.
10.	Summarise the EV battery assembly process and explain the function of its main components.

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