EV Li-ion Battery Manufacturing Techno Commercial Course

EV Li-ion battery manufacturing techno-commercial course provides practical and theoretical knowledge on setting up a lithium-ion battery assembly line, including cell selection, testing, module and pack assembly, and business aspects like costing and projections. This course prepares individuals for the EV and energy storage industries by covering technical details, cell chemistry, thermal management, and BMS, as well as commercial aspects like business planning and ROI.

EV Li-ion Battery Manufacturing Course May 23, 2025 Views 5656 Add to Reading List

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Online: Courses may be offered online, allowing for flexible learning from anywhere in India.

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EV Li-ion Battery Manufacturing Techno Commercial Course focused on EV Lithium-ion battery pack/module manufacturing provides practical skills and knowledge for setting up battery assembly lines, including cell selection, testing, module and pack assembly, and business planning. It covers both the technical aspects of Li-ion cell technology and the commercial aspects of setting up a manufacturing operation.

The EV lithium-ion (Li-ion) battery manufacturing industry is technically complex, commercially significant, and rapidly evolving. It involves a multi-step process from cell selection to battery pack assembly, with ongoing research focused on improving energy density, safety, and cost-effectiveness. Commercially, the industry faces challenges related to raw material supply chains, fluctuating prices, and the need for sustainable practices.

Technical Aspects:

Cell selection and testing: Learning to choose the right cells for a specific application and conducting internal resistance (IR) tests and charge/discharge testing.

Cell Testing:

Mastering cell Internal Resistance (IR) testing, cell balancing, and charge/discharge testing.

BMS and Thermal Management:

Understanding Battery Management Systems (BMS) and thermal management techniques.

Battery Management System (BMS): Learning about the functionality of BMS and its role in battery pack management.

Thermal management: Understanding the importance of thermal management in battery packs and different cooling methods.

Manufacturing Process:

Li-ion battery manufacturing involves several stages:

Module and Pack Assembly: Connecting cells into modules and then modules into battery packs, which are then installed in EVs.

Different product designs: Learning about different battery pack designs for various applications.

Commercial Aspects:

Market Growth:

The demand for Li-ion batteries for EVs is rapidly increasing, driven by global electric vehicle sales.

Cost Reduction:

Reducing the cost of Li-ion batteries is crucial for increasing EV affordability. Estimating the costs associated with setting up and operating an assembly line.

Investment:

Significant investments are being made in Li-ion battery manufacturing and research to support the transition to electric vehicles.

Supply Chain Resilience:

Building resilient supply chains for raw materials is crucial for ensuring the long-term viability of the industry.

Sustainability:

Adopting sustainable manufacturing practices and addressing environmental concerns related to battery production and disposal is becoming increasingly important.

Assembly line planning and layout: Designing an efficient assembly line layout.

Working capital and investment: Understanding the financial aspects of starting and running a battery pack assembly business.

Business projections: Making business projections and financial models.

Course Syllabus

1. EV Market Scenario and Business Opportunities

The global lithium-ion battery market, driven by the growth of electric vehicles (EVs) and renewable energy integration, is experiencing rapid expansion.
Topics covered:
Lithium Ion Battery Technology Overview, Battery Technology Fundamentals, Market Scenario and Business Opportunities, Lithium-ion Battery Raw Materials and India's Position, Government Policies and Incentives, Electric Vehicle Market Trends in India

Key Learning Outcomes:

Develop the ability to analyze market trends, identify growth segments, and understand the competitive landscape within the EV industry. Understand the role of government incentives and regulations in shaping the market and learn strategies for attracting investment in the EV sector.

2. Different type of Lithium-ion battery

Lithium-ion batteries are widely used due to their high energy density, light weight, and long lifespan, making them suitable for various applications, including portable electronics, electric vehicles, and energy storage systems.
Topics covered:
Battery Introduction, Battery Types, Relationship Between Power, Energy, and Applications, Comparison of Different Battery Chemistries, Advantages and Disadvantages of Lithium-ion vs. Sodium-ion Batteries, Composition and Reactivity of Lithium-ion Batteries, Key Properties of Lithium-ion Battery Chemistries, Lead-Acid Batteries, Nickel Batteries, Lithium-Ion Batteries, Lithium Battery Applications and Chemistries, Types of Lithium-Ion Batteries, Battery Cell Selection Parameters, Lithium Cobalt Oxide (LCO) Cell Characteristics, Lithium Manganese Oxide (LMO) Cell Characteristics, Lithium Nickel Manganese Cobalt Oxide (NMC) Cell Characteristics, NMC Cell for Electric Vehicles, Lithium Iron Phosphate (LFP) Battery Characteristics, LFP Battery Advantages and Disadvantages, LMFP Battery and Performance Comparison, Prismatic and Blade Cells and Battery Manufacturing and Import,
Lithium Titanate (LTO) Battery, Comparison of Battery Chemistries, C-rate Explained, Battery Overcharging and Safety, Short Circuit and Mechanical Damage Tests and Field Testing of Cell Stability

Key Learning Outcomes:

Equip students with a comprehensive understanding of Li-ion batteries - Learning about the different positive electrode materials, their synthesis, and their impact on battery performance and lifespan. Gaining knowledge on battery safety, handling best practices, and the mechanisms that lead to thermal runaway.

3. Lithium-ion Cell Parameters

Lithium-ion cell parameters define its electrical and physical characteristics. Key parameters include voltage (nominal, charge, discharge cut-off), capacity (rated and nominal), internal impedance, C-rate (discharge and charge rates), and operating temperature range. These parameters influence cell performance, lifespan, and safety.
Topics covered:
Introduction to Cell Parameters, Key Battery Parameters, Charge and Charge Capacity, Columbic Efficiency and Capacity Retention, Battery Capacity and Voltage, Nominal Voltage and State of Charge, Nominal Cell Capacity and Discharge, Temperature Effects, Actual Cell Capacity and Capacity Fade, Battery Repair and Cell Health, Open Circuit Voltage and State of Charge (SoC), Self Discharge, Continuous and Peak Current, Constant Current Constant Voltage (CCCV) Charging, Fast Charging vs. Slow Charging, C-Rate Definition and C-Rate Calculation, Impact of C-Rate on Battery Performance and Heat Generation, State of Charge (SOC) and State of Health (SOH), Open Circuit Voltage (OCV) and SOC Estimation, Internal Resistance and Temperature Effects, Cycle Life, State of Power (SOP), Battery Testing and Capacity Measurement, Causes of Battery Degradatio, Battery Restoration and Degradation, Maximum Power Point and cell Efficiency, Battery Management System (BMS), Temperature Effects on Battery Performance, Thermal Runaway and Safety, Strategies for Small Battery Manufacturers, Session Summary and Homework Assignment.

Key Learning Outcomes:

Understand Core Parameters, Learn Parameter Estimation & Measurement, Apply knowledge to evaluate and select appropriate cells for applications such as electric vehicles and portable electronic devices.

4. Lithium-ion Cell Chemistry

Lithium-ion batteries utilize the movement of lithium ions between a cathode and an anode to generate electrical current during discharge and reverse the process during charging. These ions move through an electrolyte, while electrons flow through an external circuit, creating the electric power.
Topics covered:
Lithium Ion Battery Components, Common Lithium Ion Cell Chemistry, Cathode Material and Function, Anode Material and Function, Electrolyte and Separator Roles, Solid Electrolyte Interface (SEI) Layer and Lithium Plating/Dendrite Formation, Electrochemical Reactions During Charge and Discharge, Lithium Cobalt Oxide (LCO) Cell, Lithium Nickel Cobalt Aluminum Oxide (NCA) Cell, Lithium Manganese Oxide (LMO) Cell, Lithium Iron Phosphate (LFP) Cell, Lithium Nickel Manganese Cobalt Oxide (NMC) Cell, Lithium Titanate Oxide (LTO) Cell, Anode Materials Beyond Graphite, Current Collectors, Separator Properties, Dendrite Formation and Battery Failure, Battery Life Cycle and Replacement, Recycling of Lithium-ion Batteries, Advancements in Lithium-ion Battery Technology, Quality and Manufacturing in Battery Production, Session Summary and Hometask Assignment.

Key Learning Outcomes:

Understand the physical concepts of thermodynamics and kinetics involved in electrochemical reactions, including redox principles. Learn to select appropriate battery cells and chemistries (e.g., NMC, LFP) based on specific application requirements, such as for electric vehicles.

5. Lithium-ion Cell Architecture

Lithium-ion Cell Architecture includes an anode, cathode, separator, electrolyte, and current collectors. The anode and cathode store lithium ions, the electrolyte facilitates ion transfer, the separator prevents short circuits, and the current collectors enable electron flow.
Topics covered:
Types of Cells, Cell Construction and Differences (cylindrical, pouch, prismatic, coin, or button), Internal Components and Assembly, Cylindrical Cell Casing, Anode (Negative Plate), Separator, Separator as a Safety Device, Cathode (Positive Plate), Electrolyte Injection, Electrolyte and Lithium Salts, Protection Vent and Safety Features, Current Interrupt Device (CID), Positive Temperature Coefficient (PTC) Device, Cell Casing and Additional Safety, Scalability and Cost of Battery Manufacturing, India's Manufacturing Growth, Global Business Dynamics and Dependency, Hometask Assignment.

Key Learning Outcomes:

Apply knowledge to design and develop efficient, safe, and sustainable battery solutions for industries like electric mobility and energy storage.

6. Battery Management System (BMS)

Topics covered:
Battery Management System (BMS), BMS Role in Electric Vehicles (EVs), Core Functions of BMS, Types of BMS, Key Functions of BMS: Protection, Cell Balancing, Monitoring, Communication, Customization of BMS, BMS Customization and Market Competition, Comparison of European and Chinese Technology, BMS Core Functions, Cell Imbalance Issues, Thermal Runaway Scenario, Necessity of Cell Balancing, Constant Voltage Charging and Balancing, Active Cell Balancing, DC-DC Converter Functionality, Comparison of Balancing Methods, Battery Pack and BMS Integration, BMS Operating System, Advanced BMS Functions, Battery System Control Unit, Real-Time Operation and Safety Unit, Secondary BMS Functions and Interlock System, Benefits of an Advanced BMS, Centralized vs. Distributed BMS, Protection Circuit Board (PCB) vs. BMS, BMS in Series and Parallel Connections, Battery Pack Design Considerations, Battery Thermal Management and BMS Integration, Cost and Market Considerations, Challenges in Indian Development, Home Task BMS Datasheet analysis

Key Learning Outcomes:

Understand the basic components, architecture, and functional blocks of a BMS. Learn how to monitor, estimate, and protect batteries, including cell balancing, State-of-Charge (SOC) and State-of-Health (SOH) estimation, and thermal management. Apply BMS knowledge to design, implement, and troubleshoot systems for electric, hybrid vehicles and renewable energy storage battery design.

7. Battery Thermal Management System (BTMS)

An electric vehicle's battery thermal management system (BTMS) is crucial for maintaining optimal battery performance, safety, and lifespan. It regulates the temperature of the battery pack, preventing overheating or overcooling by utilizing cooling and heating systems.
Topics covered:
Thermal Management Overview, Lithium-ion battery optimum temperature, Importance of Temperature Control, Thermal Runaway, Sources of Temperature Instability, Non-uniform Aging, Heat Generation and Dissipation, Types of Thermal Management Systems, Air Cooling System, Liquid and Refrigerant Cooling, Refrigerant cooling, Phase Change Materials and Comparison, Home Task.

Key Learning Outcomes:

Identifying and selecting appropriate components for a BTMS, including fans, pumps, heat exchangers, and controllers. Learners will understand the purpose and operation of components in air and liquid cooling systems for battery packs.

8. Lithium-Ion Cells Battery Test

Tariff Based Competitive Bidding Process for Procurement of Power from Grid Connected Solar PV Power Projects.
Topics covered:
Battery Validation Lab, Battery Cell Testing - Lithium-ion Cell actual capacity test, OCV and IR test, BMS Test, Thermal Cycling Test, Over-charging test, Bureau of Indian Standards (BIS) tests, How to get a BIS certificate,
Battery Repairing - Steps to test Battery health, IATA Lithium Battery Safety Regulations (LBSR) 2025, Lithium Battery Testing Standards

Key Learning Outcomes:

Learn various performance tests for battery cells and modules, such as those measuring capacity, voltage, and internal resistance. Enable learners to apply their knowledge to improve system performance, drive better design decisions, and ensure compliance in the energy storage market.

9. Battery Module / Pack Design

A lithium-ion battery module or pack design involves strategically arranging individual cells into modules, and then connecting those modules to achieve the desired voltage and capacity for a specific application. This design process considers factors like cell type, cooling, safety, and overall system integration.
Topics covered:
Pack Design Steps, Identify Application, Choose cell chemistry, Series –parallel configuration, Choose required BMS, Choose TMS, Choose Pack cabinet and other parts and equipments, Pack Technical Specification.
Battery Pack Cells configuration, Basic calculations that are used in battery design, Case study of different OEM battery, Module BMS connection, Custom Battery Packs - Customization Process, Collaboration between OEMs and suppliers for an optimal battery pack design, Home Task - Battery pack design, SORT analysis document.

Key Learning Outcomes:

Choose the right cell chemistry, form factor (cylindrical, prismatic or blade), and capacity based on the specific application's requirements. Identify and understand the role of components like cell holders, bus bars, insulators, and heat sinks in module construction. Evaluate the design's performance under different operating conditions.

10. Battery Pack Assembly Line and Financial Projection

Setting up a battery pack assembly line involves several key stages, from initial cell preparation to final testing and quality control
Topics covered:
KEY MANUFACTURING (PRODUCTION) METRICS, Essential quality metrics, Time Metrics, Assembly Line equipments, Market Trends in Lithium-Ion Battery Industry, Renewable Energy Storage, Electric Vehicles (EVs), Consumer Electronics, Energy Storage Solutions, How Can We Make Lithium-Ion Battery Production Cheaper, Main Revenue Streams, Financial Discloser

Key Learning Outcomes:

Developing the technical specifications for the assembly line, including equipment selection and factory layout considerations. Estimating project costs, working capital, and calculating the return on investment (ROI) for the assembly line. Creating a comprehensive business plan, including securing funding and managing financial aspects of the venture.

11. Overall discussion and Business Guide

A lithium-ion battery pack business can be profitable with careful planning and execution. Key aspects include market research, business plan development, securing funding and permits, establishing manufacturing or assembly operations, and implementing robust safety and quality control measures.
Topics covered:
Training Session Review, Project Submission and Examination,
Starting Business: Trade Name Registration, Steps to Starting a Lithium-ion battery Business, Trademark Registration, GST and MSME registrations, Website Development for Business, Business and Branding Strategy, Marketing and Promotion, Website Optimization and Visibility, Product certification, Government Initiatives, Supplier and Agency Networking, Project Proposals and Securing Work, Partnerships OEM and Post-Training Support from Academy of EV Technology.

Training Focus:

Courses cover various aspects, including Understanding lithium-ion battery chemistry, cell parameters, thermal management, and different battery chemistries used in EVs. .

Course Content Summary:

Fundamentals of Lithium-ion Batteries:

Learn about the chemistry, components, and types of lithium-ion batteries.

Battery Pack Assembly and Manufacturing:

Covers cell selection, IR testing, cell balancing, charge/discharge testing, module and pack assembling, enclosure selection, and assembly line planning.

Lithium-Ion Battery Characteristics and Basics:

Covers fundamental principles of lithium-ion batteries, including chemistry, cell parameters, and charging/discharging processes.

EV Powertrain Development:

Includes topics like battery pack design, modelling, and advanced powertrain development.

Battery Management Systems (BMS):

Includes topics like BMS functionality, architecture, cell balancing, thermal management, and BMS integration with other EV systems.

Thermal Management:

Focuses on heat transfer, thermal design of battery packs, and cooling systems.

Battery Testing:

Covers various tests for EV battery cells, modules, and packs.

Assembly Process:

Gaining hands-on experience with the assembly of battery packs, including soldering, wiring, and component placement.

Battery Pack Design and Testing:

Learning about different battery pack architectures, including module and pack design, as well as testing procedures and quality control.

Safety Procedures:

Adhering to safety guidelines during battery assembly and handling.

Business Aspects:

Learn about the business model, market analysis, financial planning, and legal requirements for starting a lithium-ion battery assembly business.

Battery Pack Assembly Line:

Sorter, Spot Welder, Discharge Tester, PVC Heat Shrink etc.

Battery Pack Assembly Plant:

BMS Tester, Aging Machine, Etc.

Target Audience:

The courses are suitable for individuals interested in becoming battery technicians, business owners, engineers, and researchers in the EV and energy storage sectors.

Who Should Attend:

Entrepreneurs looking to start a lithium-ion battery business.
Professionals seeking to enhance their knowledge in the lithium-ion battery domain.
Anyone interested in learning about battery technology and assembly.

Training Options:

Online Courses:

Online Live class courses covering the all aspects of lithium-ion battery manufacturing and assembly.

Offline Courses:

Offline hands-on training after Online classes with lab facilities and practical experience in assembling battery packs.

Benefits of Training:

Career Advancement:

Lithium-ion battery assembly training can open doors to jobs in the rapidly growing electric vehicle and renewable energy industries.

Entrepreneurship:

The training can be beneficial for entrepreneurs looking to start their own battery assembly business or plant.

Enhanced Knowledge:

Participants gain a deeper understanding of lithium-ion battery technology and its applications.

Introduce with Trainer:

Trainer: Profile Page

Mr Sanjib Roy, an expert in the field and a skilled facilitator, driving the success of their students / startups / entrepreneurs, one of the leading corporate trainers in India, facilitating a wide range of corporate training programs.
Mentorship:

He is providing guidance and support to students for their success career as startup or engineer.

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About Academy of "SR Technologist"

Academy of SR Technologist:

PV Solar and Electric Vehicle (EV) training institutes offer programs to equip individuals with the knowledge and skills needed for the growing PV Solar and EV industry. These programs range from introductory courses to specialized advanced certifications.

For PV Solar Sector:

We cover topics like solar PV system design, installation, maintenance, and troubleshooting. Institute provide practical training and theoretical knowledge, preparing graduates for jobs in the industry or to start their own solar businesses.