*TRAINING SYLLABUS:*
*Training Duration:* 8 weeks
*MODULE 1: INTRODUCTION TO LITHIUM BATTERIES*
*1. COURSE OVERVIEW*
– Introduction to the course and its objectives.
– Overview of the practical applications in various fields, including solar installations, electric vehicles, security camera, home automation and other electronic devices.
*2. BASIC CONCEPTS AND COMPONENTS*
– How lithium battery cells work and store energy.
– How lithium batteries are deployed across various industries.
*3. TYPES AND FORM FACTORS OF LITHIUM CELLS*
FORM FACTORS:
– Pouch cells
– Prismatic cells
– Cylindrical cells
TYPES OF LITHIUM
– Lithium Ion (Li-ion)
– Lithium Manganese Oxide (LiMn2O4 or Li-manganese)
– Lithium Cobalt Oxide (LiCoO2, Li-cobalt)
– Lithium Nickel Manganese Cobalt Oxide (LiNiMnCoO2 or NMC)
– Lithium Nickel Cobalt Aluminum Oxide (LiNiCoAlO2, NCA or NCR)
– Lithium Polymer (Li-poly or Lipo)
– Lithium Iron Phosphate (LiFePO4)
– Summary of Lithium Battery Technology
– Comparison of different types and their suitable applications.
*MODULE 2: SAFETY AND HANDLING*
*1. SAFETY FUNDAMENTALS*
– Importance of safety in handling lithium batteries.
– Personal Protective Equipment (PPE) requirements.
*2. RISK MANAGEMENT*
Danger of Short Circuits:
– How short circuits occur and their consequences.
Temperature Effects:
– Impact of temperature on lithium cell performance and safety.
Handling and Storage:
– Safe handling techniques and proper storage conditions.
Emergency Procedures:
– Steps for dealing with battery leaks, spills, and fires.
-Disposal and Recycling:
– Environmentally safe disposal methods and recycling importance.
*MODULE 3: SOURCING AND EVALUATING BATTERY CELLS*
*1. SOURCING LITHIUM BATTERY CELLS*
Buying New Cells:
– Identifying reliable suppliers and how to ship components from China.
Using Salvaged Cells:
– Disassembling and evaluating battery cells from discarded devices like power banks and laptop battery packs
Buying Used Electric Vehicle Battery Modules:
– Assessing the condition and suitability of used EV battery modules.
*2. TESTING AND EVALUATING CELLS*
– Tools and techniques for testing cell voltage, capacity, and internal resistance.
– Criteria for selecting good cells based on performance metrics and physical condition.
*3. CELL RATINGS AND PERFORMANCE*
Understanding cell ratings:
– Capacity
– Maximum discharge rate
– C-rate (charge/discharge rate)
– Maximum charge rate
– Maximum number of cycles
*MODULE 4: DESIGNING AND SIZING BATTERY PACKS*
*1. BATTERY PACK DESIGN PRINCIPLES*
– Determining required voltage and capacity for specific applications.
– Calculating series and parallel connections to meet desired specifications.
*2. BATTERY LAYOUT AND DESIGN*
– Designing layouts for balance, space efficiency, and thermal management.
Voltage and Capacity:
– Planning the electrical characteristics and capacity of the pack.
Current Rating and Cycle Life:
– Choosing cells based on current demands and longevity.
Physical Considerations:
– Weight, size, and safety in design.
Grouping Cells:
– Arranging cells for optimal performance and safety.
Making Different Battery Shapes:
– Adapting pack designs to fit various form factors.
*3. BATTERY MANAGEMENT SYSTEMS (BMS)*
Importance and Role of BMS:
– Monitoring, balancing, and protecting the battery pack.
*MODULE 5: ASSEMBLING BATTERY PACKS*
*1. PREPARATION FOR ASSEMBLY*
– Setting up a safe and organized workspace.
– Gathering necessary tools and materials: Spot welders, soldering irons, insulation materials.
*2. LITHIUM BATTERY CELL CONNECTION TECHNIQUES*
Series and Parallel Connections:
– Techniques for connecting cells to increase voltage and capacity.
Connection Methods:
– Spot welding, soldering, bolted connections, and wire connectors.
Ensuring Reliable Connections:
– Tips for making strong, dependable electrical connections.
*3. CONSTRUCTION METHODS*
Physically Holding Cells Together:
– Strategies for securing cells in the pack.
Cell-Level Fuses:
– Incorporating fuses for safety and protection.
BMS Installation and Testing:
– Properly securing and wiring the BMS.
– Connecting charge, discharge, and balance wires.
– Initial testing to ensure proper function before final assembly.
*4. ENCAPSULATION AND FINAL ASSEMBLY*
– Insulating and protecting individual cells and connections.
Sealing the Battery Pack:
– Using hard cases, heat shrink, and addressing cooling issues.
*MODULE 6: QUALITY CONTROL AND PERFORMANCE TESTING*
*1. INITIAL TESTING PROCEDURES*
– Checking voltage and connections.
– Basic load testing for initial performance evaluation.
*2. PERFORMANCE TESTING AND CALIBRATION*
– Testing capacity and efficiency.
– Balancing cells and ensuring even performance across the pack.
*3. LONG-TERM RELIABILITY TESTING*
– Simulating charge/discharge cycles to test longevity.
– Monitoring temperature and performance over extended use.
*4. TROUBLESHOOTING AND REPAIRS*
– Identifying common issues and diagnosing problems.
– Safe methods for repairing and maintaining battery packs.
*MODULE 7: INTEGRATING BATTERY PACKS WITH SYSTEMS*
*1. BASICS OF SOLAR ENERGY SYSTEMS*
– Overview of solar panels and their specifications.
– Matching battery packs with solar panel output.
*2. CONNECTING BATTERY PACKS TO SOLAR INSTALLATIONS*
– Wiring and connection methods.
*3. CHARGING LITHIUM BATTERIES*
*Charging Methods:*
– Constant Current, Constant Voltage (CC/CV) charging.
– Charging with and without a BMS.
Charging Temperature:
– Best practices for safe and efficient charging.
*Increasing Cycle Life:*
– Strategies for extending battery life: lower voltage charging, reduced discharge currents, and temperature management.
*MODULE 8: PRACTICAL BATTERY FABRICATION PROCEDURES*
*1. DISASSEMBLY AND RECYCLING OF USED POWER PACKS*
– Hands-on practice in safely disassembling various battery packs.
– Identifying and categorizing cells for reuse.
*2. CELL TESTING AND EVALUATION*
– Practical methods for testing cells using multimeters and analyzers.
– Documenting and analyzing test results to select suitable cells.
*3. BATTERY PACK ASSEMBLY PROJECTS*
– Building functional battery packs from selected cells.
– Integrating BMS and other safety components into the pack.
*4. SOLAR SYSTEM INTEGRATION PROJECTS*
– Setting up and testing small-scale solar installations with the assembled battery packs.
– Evaluating the complete system for performance and reliability.
*5. EXAMPLES OF BATTERY BUILDING PROJECTS*
– Designing practical projects such as:
– 5V/12v backup battery and USB device charger.
– 12s RC lipo electric skateboard battery.
– 10s (36V) electric bicycle triangle battery.
– 38s (120V) LiFePO4 prismatic cell electric car battery.
– 14s (52V) 18650 home energy storage battery.
– 4s (14.8V) 18650 RC drone or FPV battery.
– Designing various capacities of lithium battery packs for solar installation applications:
1. 12V/50A BATTERY
2. 12V/100A BATTERY
3. 24V/150A BATTERY
4. 48V/200A BATTERY
5. 15Kwh lithium battery.
*MODULE 9: BRANDING, MARKETING, AND CONCLUSION*
*1. BRANDING AND MARKETING YOUR BATTERY SOLUTIONS*
– Developing a brand identity for your battery packs.
– Creating effective marketing strategies to promote your products.
*2. SHOWCASING AND DOCUMENTING PROJECTS*
– Professional presentation and documentation of battery fabrication projects.
– Highlighting technical specifications and performance features.
*3. RECAP AND COURSE CONCLUSION*
– Reviewing key concepts and skills learned throughout the course.
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