Hands-On Learning, Powering America Forward

Battery Pack Design and Safety: Assembly, Components, and High-Voltage Safety

 

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CONTENT TYPE

VR, 3D ILV, Interactive Modules

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DURATION

2.5 Hours

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TARGET AUDIENCE

Technician

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COURSE DELIVERY

VR and Web-based

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Credits : -

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About the Course:

This Battery Pack Design and Safety microcredential provides a comprehensive overview of electric vehicle (EV) battery pack design, from historical foundations to modern assembly practices and safety protocols, making it an ideal skill-building course for aspiring electric vehicle technicians. Learners explore every critical component of battery systems including cells, modules, sensors, busbars, fuses, and control units while developing hands-on skills in thermal management, sealing, and wiring. Virtual Reality (VR) modules enhance learning by simulating real-world tasks like PPE usage, component identification, and safety inspections in high-voltage environments.

Learning Objectives:

  • Understand the historical development of battery technology, from static electricity to modern EV packs.
  • Identify the structure and assembly process of battery cells, modules, and packs.
  • Apply proper thermal management strategies using adhesives and thermal transfer materials.
  • Follow PPE requirements and hazard mitigation strategies in battery assembly environments.
  • Recognize and describe key components of a battery pack, including busbars, contactors, fuses, and sensors.
  • Understand high-voltage safety systems such as precharge circuits and battery management systems (BMS).
  • Define and interpret HV battery health monitoring terms like SOC, SOH, SOP, and RUL.
  • Participate in immersive VR simulations for component identification and PPE best practices.

Course delivered via LMS and requires an Oculus VR headset for hands-on VR simulations.

EV battery pack design and safety training showing technician assembling cells and modules

 

Workforce Development

EV battery pack design and safety training with immersive learning modules at ImmerseLearn

At ImmerseLearn, we prepare EV technicians through our Electric Vehicle Technician Program for the demands of advanced battery technology and electric propulsion systems. This course emphasizes both technical knowledge and workplace safety, enabling learners to confidently contribute to EV assembly, service, and diagnostics.

Historical Context and Technical Foundation −
Explore early battery innovations—from Volta’s pile to modern lithium-ion cells—and their influence on today’s battery systems.
Component Mastery +
Gain hands-on experience with critical elements such as busbars, wiring harnesses, contactors, precharge circuits, and fuses.
Thermal and Mechanical Design +
Learn how to ensure thermal stability and seal integrity using adhesives, fasteners, and gaskets.
Safety and Hazard Mitigation +
Recognize workstation hazards and utilize appropriate PPE in high-voltage environments through guided VR exercises.
High-Voltage Monitoring and Management +
Interpret data from BMS and onboard sensors to assess battery state-of-health and predict remaining useful life (RUL).
VR-Based Component Familiarization +
Interactively explore battery pack components and safety gear using immersive VR scenarios, reinforcing theory with practice.


By completing this microcredential, students will be prepared to work safely and effectively with modern EV battery systems contributing to the development and maintenance of high-performance, reliable electric vehicles.