Battery Pack Design and Development : Fundamentals

Last Day for Registration : May 26, 2025

Register before the 30th of April, 2025 to avail an Early Bird Discount of Rs. 47,200  Rs. 37,760 (Rs. 32,000 + 18% GST)

SKU: IIT Madras | Start Date: 6th June, 2025 Categories: ,

Course Description

The rapid electrification of transportation is transforming how we design and develop energy storage systems. At the heart of every electric vehicle (EV) lies its battery pack—a complex system that must be carefully engineered for performance, safety, and longevity. This course, Battery Pack Design and Development: Fundamentals, provides a comprehensive foundation in the key principles governing battery technology, from fundamental cell chemistry to system-level integration.

This course will give the attendees insights into vehicle power and energy requirements, EV subsystems, cell characterization, mechanical design, thermal design, battery management system (BMS), and battery management strategies, including SOC, SOH, SOP, and safety concerns. Attendees will explore critical aspects of mechanical, thermal, and electrical design, ensuring that a battery pack can withstand real-world challenges. Advanced topics, including machine learning-based state estimation, fault diagnostics, and energy optimization, will prepare the attendees for next-generation battery systems.

Mastering these concepts will enable the attendees to tackle real-world challenges in designing efficient, safe, and sustainable battery packs. Whether the attendees are engineers, researchers, EV enthusiasts, students, including beginners, this course will empower them to shape the future of electric mobility. Let us drive innovation with fun together!

Instructors

Prof. Atriya Biswas is a Post-doctoral Research Associate in one of the best Powertrain Electrification and Autonomous Vehicle programs in the world. He has defended his Ph.D. thesis on a Deep Reinforcement Learning-based Energy Management System for Hybrid Electric Vehicles. Currently, he is leading a group of graduate students in an industry project and supervising them in their Ph.D. and master’s theses. Besides working on his core focus of control and system design for powertrains for HEVs, he has a research collaboration with the Fiat Chrysler Automotive group in developing a state-of-the-art control system model for optimizing HEV performance, fuel efficiency, and emissions. Neural networks, adaptive control, and the estimation of the state and parameters of nonlinear systems are a few of his current research interests. Control system design for various autonomous systems will be his future research focus.

 

 

Dr. Kaushal Kumar Jha is the Principal Investigator and Founder of NoonRay Energy Pvt. Ltd. NoonRay specializes in thermal and Energy management solutions for Automotive, EV, Aerospace, Commercial HVAC, and Electronics. He consults for various organizations in the fields of Automotive, Thermal, and Energy Management. He is an Adjunct Professor in the Department of Engineering Design at IIT Madras. He is also the CEO of the Centre for Battery Engineering and Electric Vehicle – CBEEV at IIT Madras and the Centre for Excellence in Energy and Telecommunication, (CEET), an R&D Society of IIT Madras where he contributes to India-specific cutting-edge R&D in Li-ion Battery Packs, Motor Thermal Management, Charger Development, Management & Analytics and Recycling of Li-ion cells. He holds a Ph.D. from IIT Madras in Mechanical Engineering and has more than 14 years of experience in Industrial and Academic R&D.

Module Description

MODULE – 1 : Introduction to Vehicle Electrification and Power Requirements

Module Description:

Introduces the fundamental power and energy requirements for electric vehicles (EVs) and their subsystems

Concepts Covered:

Vehicle dynamics, power and energy demand, motor-battery interaction, auxiliary loads.

Learning Outcomes:

Understand the power and energy demands of EVs, the role of batteries, and system constraints.

Applications of the Module:

EV system design, powertrain selection, energy-efficient mobility solutions.

MODULE – 2 : Battery Cell Fundamentals and Characterization

Module Description:

Covers different battery cell types, form factors, chemistry, and characterization parameters.

Concepts Covered:

Battery form factor, capacity, C-rate, chemistry, SOC, SOH, voltage, current, temperature, degradation, cycle life, calendar life.

Learning Outcomes:

Differentiate between battery chemistries and performance characteristics, understand key cell parameters.

Applications of the Module:

Selection of battery cells for different EV applications, battery diagnostics, and monitoring.

MODULE – 3 : Cell Costing, Pack Structuring, and Integration

Module Description:

Discusses cost analysis of battery cells and theoretical frameworks for pack structuring.

Concepts Covered:

Cell-level costing, mPnS theory, packaging space, thermal/electrical/electronic integration.

Learning Outcomes:

Analyze battery cost implications, understand modular structuring of packs.

Applications of the Module:

Cost optimization in battery production, design trade-offs in pack assembly.

MODULE – 4 : Mechanical and Thermal Design of Battery Packs

Module Description:

Focuses on the mechanical and thermal aspects of battery pack integration..

Concepts Covered:

Mechanical constraints, stress/strain analysis, vibration resistance, IP rating, venting, heat load calculations, thermal management for 2W/4W.

Learning Outcomes:

Understand the structural and thermal challenges in battery pack design.

Applications of the Module:

Development of robust, vibration-resistant, and thermally efficient battery packs.

MODULE – 5 : Electrical Design and Integration of Battery Packs

Module Description:


Covers the electrical architecture, connections, and safety aspects of battery packs.

Concepts Covered:

Current calculations, bus bar design, parallel paths, voltage balancing, thermal impact on electrical connections.

Learning Outcomes:

Learn how to design efficient electrical connections in a battery pack.

Applications of the Module:

Optimizing electrical pathways for reduced resistance and improved thermal stability.

MODULE – 6 : Introduction to Battery Management Systems (BMS) and Modeling

Module Description:


Provides an overview of BMS and modelling approaches used for performance prediction.

Concepts Covered:

Provides an overview of BMS and modelling approaches used for performance prediction.

Learning Outcomes:

Understand the role of BMS and different modelling techniques used in battery performance estimation.

Applications of the Module:

Implementing BMS in battery packs for real-time monitoring and control.

MODULE – 7 : State Estimation and Monitoring in BMS

Module Description:

Explains the key functions of BMS related to monitoring and protection

Concepts Covered:

SOC estimation (Coulomb counting, Kalman filtering), SOH estimation (direct vs. indirect methods), cell balancing, and protection mechanisms

Learning Outcomes:

Learn different methods for state estimation and their importance in BMS.

Applications of the Module:

Improving BMS accuracy, extending battery life, and ensuring pack safety.

MODULE – 8 : Advanced State Estimation and Control Strategies

Module Description:

Covers machine learning (ML) applications in battery management and state estimation techniques

Concepts Covered:

Data-driven SOC/SOH estimation, ML-based models, SOP estimation techniques.

Learning Outcomes:

Apply ML techniques for better battery state predictions and control strategies.

Applications of the Module:

AI-driven BMS, real-time state estimation, and predictive maintenance.

MODULE – 9 : BMS Communication, Fault Diagnostics, and Safety

Module Description:


Focuses on communication protocols and fault management in battery packs.

Concepts Covered:

CAN, Modbus, LIN, wireless BMS, fault detection, thermal runaway, safety standards (ISO 26262, UL 2580).

Learning Outcomes:

Understand how BMS communicates and detects faults for enhanced safety and reliability.

Applications of the Module:

Designing fault-tolerant BMS, ensuring compliance with safety standards.

MODULE – 10 : Battery Pack Testing, Recycling, and Sustainability

Module Description:


Discusses testing methodologies and sustainable battery lifecycle management.

Concepts Covered:

Performance and safety testing, second-life applications, recycling techniques, circular economy in battery manufacturing.

Learning Outcomes:

Learn best practices for battery testing, disposal, and reusability.

Applications of the Module:

Sustainable battery design, recycling processes, and second-life applications.

Eligibility & Fees

Fees: Rs. 47200 (Rs. 40000 + 18% GST)

Register before the 30th of April, 2025 to avail an Early Bird Discount of Rs. 47,200  Rs. 37,760 (Rs. 32,000 + 18% GST)

 

Certification

Certificate criteria for this course would be as follows:

Total % will be calculated from all 3 categories( Assignments, Quizzes and Attendance of Live sessions)

Type of certificate that will be issued
75% -100% Successfully completed
50% -74% Completed
25% – 49% Participated
<25% No Certificate

Course Certificate Template

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