Battery Assembly & BMS
Build repeatable battery assembly, BMS diagnosis and performance-testing practice with equipment designed for supervised teaching. Keep electrical limits and safety procedures clear from the start.
The Training Route
Connect cell and pack assembly with BMS interpretation, then use a compatible performance station to explain the battery’s measured response.
Measure and sort cells, assemble the teaching module and pack, and complete the specified connection and component checks.
Record cell measurements and assembly inspections before progressing to the next exercise.
Compare physical readings with BMS and CAN information during instructor-selected fault exercises.
Explain the relationship between the measured circuit condition and the reported battery data.
Run approved charge-discharge and DC internal-resistance exercises on the matched performance station, recording battery state and test settings.
Use recorded conditions to interpret capacity, resistance and charge-discharge results.
The Equipment Combination
Use T028 for cell measurement, pack assembly and BMS diagnosis. Add a compatible T068 performance station when the course includes charge-discharge, capacity and DC internal-resistance analysis.
Training Equipment
Practice supervised battery assembly, electrical measurement and fault investigation with BMS monitoring software.
Training Equipment
Investigate battery capacity and internal resistance through programmable charging cycles and test-data analysis.
| Item | Teaching Configuration |
|---|---|
| Teaching pack | T028: LFP, nominal voltage ≥60 V; pack 884 × 530 × 230 mm; individual cell 3.2 V / 30 Ah. |
| BMS | Supply DC 9–36 V; cell-voltage sampling accuracy ≤5 mV; temperature detection accuracy ±1 °C. |
| On-board charger | Output ≥75 V DC, ≤10 A, ≥800 W; efficiency ≥0.93; IP65; CAN 2.0. Confirm compatibility and approved pack limits. |
| Tools and instruments | 1 kV withstand-rated insulated tool set; internal-resistance tester with 0.1 mΩ resolution; insulation resistance range 2,000 MΩ; ground resistance meter and digital multimeter. |
| Performance tester | T068: rated power ≤4 kW; 380 V three-phase supply; charge 0–100 V DC, discharge 10–100 V DC; channel current −30 to +30 A. |
| Performance measurement | Voltage and current accuracy: 0.05% full scale + 0.05% of reading; energy recovery efficiency ≥80%. Battery limits govern each test. |
| Training tasks | Cell measurement and sorting, module and pack assembly, BMS interpretation, contactor and pre-charge inspection, controlled fault diagnosis and charge-discharge data analysis. |
| Teaching cycle | Repeated student-group use with pre-operation inspection, component-condition checks and instructor-controlled fault selection. |
From Equipment to Teaching
Organize group practice around handling, assembly inspection, BMS interpretation and recorded test results, with a supervised inspection and reset sequence between exercises.
Teach battery handling at the designated station with qualified supervision, specified protective equipment and approved isolation and verification procedures. Use the approved teaching controls for fault exercises so each group follows the same supervised work sequence.
Use accessible, serviceable teaching components and an inspected assembly sequence for repeated group practice. Keep full vehicle-pack demonstrations within their approved scope, and use course media to connect the teaching pack with full-size battery architecture.
Ask learners to connect physical readings with BMS sensing, CAN communication and documented on-board charger behavior. Assess how they explain the relationship between the circuit condition and reported data, alongside the accuracy of the measurement.
Set approved voltage, current and stop conditions, then record battery state and test settings for each exercise. Use the T068 measurement specification and calibration evidence when comparing results, with the energy-recovery connection planned during site commissioning.
Use the LFP teaching station for cell measurement, pack assembly and BMS interpretation. Combine instructor-selected fault exercises with performance records from a compatible test station.
Organize group practice around inspection, measurement and a recorded explanation of the result. Keep the teaching pack, full-size vehicle references and performance tester within their separately documented scopes.
Project Experience & References
Connect the course to the cited occupational standard, applicable 1+X tasks and the technical files for the named competition configuration.
The “Replacing Power Battery Modules” unit for Beijing Changping Vocational School combines PPT, animation and video around a GEELY/CATL 53 kWh / 353 V pack. The national competition reference vehicle, Geometry G6, uses a separate 52.8 kWh / 352 V liquid-cooled pack.
These are distinct reference systems. They do not change the ratings of T028 or T068. The company’s wider delivery record spans 1,000+ customer institutions across 30 provinces.
T028 specifies BMS sampling accuracy ≤5 mV and internal-resistance resolution of 0.1 mΩ. T068 specifies voltage and current accuracy of 0.05% full scale plus 0.05% of reading.
Request the current model specification, instrument and calibration documents, teaching task sheets and applicable competition technical files. The quotation must identify the battery, instruments, software and permitted test limits.
Application FAQs
No. The T028 specification states nominal voltage ≥60 V, and its stored energy can still cause serious harm. Use trained supervision, approved isolation and verification procedures, the equipment manual and the institution’s protective measures.
T028 provides cell, pack and BMS practical work. T068 adds programmable charge-discharge, capacity and DC resistance analysis. Their combination connects correct assembly with measured performance; each station retains its own operating limits.
Only after a project-specific compatibility and safety review. A vehicle pack’s chemistry, voltage, current, connectors and BMS may exceed the teaching equipment’s limits. Real-pack course media can add context without making daily learner disassembly the default.
