Battery module

A battery module is an assembly consisting of one or more battery cells and often includes additional components such as sensors, protection circuits and cooling. The battery cells can be connected in series or parallel to achieve a higher voltage or capacity. The battery module housing protects the cells from external influences and can be made of metal, plastic or other materials.

How are battery modules constructed?

Battery modules differ greatly depending on the manufacturer and the application. However, some elements are typically found in battery modules:

  1. Battery cells: They are the most important component responsible for storing and releasing electrical energy.
  2. Physical connections: The battery cells are interconnected to achieve the desired voltage and capacity. The connections can be made by screwing, welding, soldering or other methods.
  3. Housing: The housing of the battery module protects the battery cells from external influences such as vibration, shock, moisture and dust.
  4. Cooling: Battery modules can become warm, especially if they are charged or discharged quickly. Cooling components such as fans, heat sinks or cooling fluids help to prevent overheating.
  5. Battery Management System (BMS): It monitors and controls the performance of the battery and protects it from damage due to overcharging, overdischarging or overheating. Not every battery module has its own battery management system. As a rule, modules are controlled by the BMS of the overall battery.

Dangers when using battery modules

All electrochemical systems present certain hazards that must be taken into account during use, but also during transportation and storage. The decisive factors for the hazards can be the production quality, aging, but also sudden environmental influences. With the help of NOVUM technology, potential risks can be identified before real problems arise.

Companies should definitely keep an eye on the following risks:

  • Thermal Runaway: A short circuit, but also overcharging as well as physical effects can cause batteries to overheat and explode.
  • Leakage of hazardous vapors and liquids: Caution! Batteries may leak. In addition, if vapors are formed, it means that the battery is overheated and may catch fire and explode.
  • Electrocution: High voltages can cause serious injuries, so proper handling of battery modules is particularly important
  • Environmental damage: Batteries always have components that are harmful to health, so it is imperative that they be disposed of properly.

Can battery modules be checked using NOVUM technology?

Yes — and quickly, inexpensively and non-invasively! With our battery analyzer we can test single cells as well as packs and modules. Within seconds, our AI can provide you with reliable statements on the following aspects:

  • Production quality and formation
  • State of Charge (SoC)
  • State of Health / State of Wear (SoH)
  • Capacity
  • Expected life
  • Battery residual value
  • Anomalies that can lead to defects and failures

Depending on what you want to do with your used battery modules, it may also make sense to open the housings and test individual cells. In our Cell Analyzer, we can individually check eight cells within seconds.

We will be happy to advise you on which process is best for your purposes and how you can profitably use your battery modules or individual cells in a second or third life.


Ingolf Bachmann

Office Manager

We will be happy to answer your questions!