Postgraduate Diploma in Connectors, Busbars and Electrical Balancing
Online 800-hour Postgraduate Diploma in connectors, busbars and electrical balancing. 8 modules covering ISO 6469-3, UNECE Regulation No. 100 and ANSYS Mechanical. Assigned tutor and open enrolment.
Take the controls.
Run a real engineering trade-off from this field. Move the sliders, watch the model react in real time and beat the challenge.
What you will be able to do
Size copper and aluminium busbars according to electrical and thermal criteria.
Select high-voltage connectors with HVIL and an appropriate IP rating.
Evaluate cell-to-busbar joining processes and their failure modes.
Design reliable sensing harnesses for battery modules.
Compare passive and active balancing strategies.
Plan insulation, hipot and thermal cycling tests.
Document a pack interconnection system ready for manufacturing.
Who it's for
- Battery pack design engineer looking to specialise in Connectors, Busbars and Electrical Balancing.
- High-voltage electrical engineer looking to specialise in Connectors, Busbars and Electrical Balancing.
- Component validation engineer looking to specialise in Connectors, Busbars and Electrical Balancing.
- BMS specialist looking to specialise in Connectors, Busbars and Electrical Balancing.
- Joining process engineer looking to specialise in Connectors, Busbars and Electrical Balancing.
- Supplier quality manager looking to specialise in Connectors, Busbars and Electrical Balancing.
- Engineering or science graduates seeking to enter electric automotive.
What you'll work with
- ISO 6469-3
- UNECE Regulation No. 100
- IEC 60664-1
- LV 215-1
- USCAR-2
- ISO 20653
- SAE J1742
8 modules · 800 h
1.1Series-parallel topologies and xSyP configuration1.2Current sharing between cells in parallel1.3Contact resistance and its impact on the pack1.4Main and auxiliary current paths1.5400 V and 800 V platforms1.6Creepage distances and galvanic isolation1.7Fuse and pyrofuse coordination1.8Main contactors and precharge circuit1.9Electric shock protection requirements1.10Workshop: single-line diagram of a 96S2P pack
2.1Copper, aluminium and bimetallic busbars2.2Cross-section based on permissible current density2.3Joule heating and thermal gradients2.4Laminated busbars and parasitic inductance reduction2.5Tin, nickel and silver coatings2.6Insulation with polyimide, PET and powder coating2.7Flexible versus rigid busbars2.8Geometric tolerances and thermal expansion2.9Electrothermal finite element simulation2.10Practice: sizing a busbar for 300 A continuous
3.1Laser welding of cylindrical and prismatic cells3.2Ultrasonic welding of pouch tabs3.3Wire bonding and integrated cell fuse3.4Bolted joints and torque control3.5Galvanic corrosion in copper-aluminium joints3.6X-ray inspection of welds3.7Tensile and peel testing of joints3.8Joint reliability under thermal cycling3.9Typical defects and root cause analysis3.10Laboratory: four-wire contact resistance
4.1HV connector types in electric vehicles4.2HVIL interlock loop4.3IP67 and IP6K9K protection ratings4.4Shielding and electromagnetic compatibility4.5Manual service disconnect and service connectors4.6Current derating with temperature4.7Mating cycles and contact wear4.8Connector testing to LV 215 and USCAR-24.9Selection of shielded cable and terminals4.10Case study: connector for an 800 V inverter
5.1Cell voltage sensing harnesses5.2Flexible FPC circuits in modules5.3Integrated cell contact system5.4NTC thermistor mounting5.5Daisy chain communication between AFEs5.6Protection of sensing lines against short circuit5.7Fretting in signal contacts due to vibration5.8Continuity and insulation verification5.9Measurement errors caused by harness voltage drop5.10Workshop: sensing harness for a 12S module
6.1Origin of imbalance: capacity, self-discharge and temperature6.2Passive balancing through resistive dissipation6.3Active capacitive and inductive balancing6.4DC/DC converters for equalisation6.5Voltage-based versus SoC-based strategies6.6Balancing current and equalisation times6.7Thermal management of balancing resistors6.8Balancing functions in commercial AFEs6.9Effect of balancing on usable capacity6.10Practice: passive balancing simulation for 16 cells
7.1Dielectric strength (hipot) test7.2Insulation resistance according to ISO 6469-37.3External short circuit of the pack7.4Thermography of joints under load7.5Voltage drop across busbars at rated current7.6Thermal shock of joints and connectors7.7Vibration applied to connections7.8Analysis of connectors returned from the field7.9DVP&R plan for the interconnection system7.10Case study: busbar validation report
8.1Electrical requirements specification8.2Selection of topology and materials8.33D modelling of busbars and connectors8.4Justified electrothermal calculation8.5Reasoned choice of balancing strategy8.6Test plan and acceptance criteria8.7System design FMEA8.8Manufacturing documentation8.9Report and presentation8.10Final review with the tutor
How you'll learn
Fully 100% online training on the SEIUM Institute campus, with downloadable material, recorded classes and an assigned technical tutor. No fixed timetable: students progress at their own pace within the intake, making it easy to combine with work.
Each module combines theory, guided reading of the original standard and applied exercises. The working software is ANSYS Mechanical, COMSOL Multiphysics, CATIA V5, MATLAB/Simulink, Siemens Capital, in free, academic or evaluation versions. The tests are studied using real procedures for sizing busbars for high-voltage packs, validating welded joints in modules, and selecting balancing strategies in BMS. Assessment is continuous per module plus the final integrating project.
Build it end to end
Your final project follows the real engineering workflow, step by step, reviewed by your tutor.
Size copper and aluminium busbars according to electrical and thermal criteria.
Select high-voltage connectors with HVIL and an appropriate IP rating.
Evaluate cell-to-busbar joining processes and their failure modes.
Design reliable sensing harnesses for battery modules.
Compare passive and active balancing strategies.
Where this takes you
Requirements
- Prior technical training or professional experience in the sector. A university degree is not required.
- Internet connection and a computer capable of running the programme's software.
- Sufficient English to follow technical standards documentation.
Ready to start?
Send your application today. Our admissions team replies within 72 hours with your study plan and funding options.
Frequently asked questions
The programme comprises 800 hours in total, spread over 6 to 8 months. That is an average of 10 to 15 hours per week, compatible with a full-time job.
You will work with ANSYS Mechanical, COMSOL Multiphysics, CATIA V5, MATLAB/Simulink, Siemens Capital. Free, academic or evaluation versions are used, and the tutor indicates the free alternative where one exists.
An SEIUM Institute own diploma upon passing the continuous assessment and the integrating project. It is in-house training, not an official qualification from the Ministry.
Yes. Modules passed in a course or postgraduate diploma in the same area are credited towards the advanced programme. Check the credit transfer policy when you enrol.
Related programmes
Postgraduate Diploma in BESS Integration and Traction Substations
800 h online Postgraduate Diploma in BESS and Traction Substation Integration. 8 modules with EN 50328, EN 50329 and OpenPowerNet. Assigned tutor and open enrolment.
Postgraduate Diploma in NVH of Electric Transmissions and Thermal Lubrication
Online 800-hour Postgraduate Diploma in NVH of Electric Transmissions and Thermal Lubrication. 8 modules covering ISO 8579-1:2002, ISO 3744:2010 and Simcenter Testlab. Dedicated tutor and open…
Postgraduate Diploma in Sharing Operations and Urban Data
Online 800-hour Postgraduate Diploma in Sharing Operations and Urban Data. 8 modules covering Regulation (EU) 2016/679, the General Bikeshare Feed Specification (GBFS) and Python. Assigned tutor…
More in Electromobility, Batteries & Hydrogen
All Electromobility, Batteries & Hydrogen programmes → · How to apply · Fees & financing · Scholarships