Motive Power Batteries and Battery Management Systems

This course provides technicians with specialized knowledge of energy storage architectures powering modern electric material handling equipment. Students explore the electrochemistry, construction, and operational characteristics of industrial lead-acid and lithium-based traction packs. Core competencies include analyzing State of Charge (SoC) using open-circuit voltage calculations such as $V_{cell} = \text{SoC} \times 0.01 + 1.95$ for standard chemistries, state-of-health assessments, specific gravity hydrometry, and advanced Battery Management System (BMS) communications. Instruction emphasizes high-voltage safety, cell monitoring, active and passive balancing strategies, thermal runaway prevention, and contactor control circuits. Through progressive theoretical analysis and intensive workshop investigations, technicians develop structured fault-isolation routines for energy storage units. Students learn to safely inspect, service, rebuild cell connections, calibrate telemetry sensors, and commission replacements. By mastering these industrial power storage platforms, technicians ensure maximum energy efficiency, prolong pack service life, and maintain rigorous fleet safety standards across diverse material handling environments.

InstructorJacob Calhoun