Title: Assignment: Module 1: Battery Construction & Types - Activity
Course: ASE A6 Battery Service

Activity: Battery Component Identification & Assembly

Overview

Detail | Value
Type | Hands-on lab + written worksheet
Duration | 45-60 minutes
Materials | 3D printed battery model (disassembled), worksheet (below)
Grading | 50 points total

Objectives

Students will:

1. Identify and name all major battery components by handling them physically
2. Assemble the 3D battery in the correct order
3. Explain the function of each component in writing
4. Count and verify correct component quantities per cell and per battery

Part 1: Component Identification (20 points)

Instructions: Your instructor will provide a disassembled 3D battery model. Identify each component, write its name, and describe its function.

# | Component | Real-World Material | Function | Points
1 | _________________ | Polypropylene | _________________ | 2
2 | _________________ | Lead alloy (positive) | _________________ | 2
3 | _________________ | Lead alloy (negative) | _________________ | 2
4 | _________________ | Lead dioxide (PbO2) | _________________ | 2
5 | _________________ | Sponge lead (Pb) | _________________ | 2
6 | _________________ | Microporous PE / Glass mat | _________________ | 2
7 | _________________ | H2SO4 + H2O | _________________ | 2
8 | _________________ | Lead | _________________ | 2
9 | _________________ | Lead | _________________ | 2
10 | _________________ | Lead | _________________ | 2

Answer Key:

1. Case — Houses all internal components, divided into 6 cell compartments
2. Positive plate grid — Holds PbO2 paste and conducts current
3. Negative plate grid — Holds Pb paste and conducts current
4. Positive plate paste — Active material that accepts electrons during discharge
5. Negative plate paste — Active material that supplies electrons during discharge
6. Separator — Prevents plate contact while allowing ion flow
7. Electrolyte — Carries ions between plates, participates in chemical reaction
8. Positive post — External connection point for positive terminal
9. Negative post — External connection point for negative terminal
10. Cell strap — Connects cells in series (positive group to negative group)

Part 2: Battery Assembly (15 points)

Instructions: Assemble the 3D battery model in the correct order. Your instructor will observe and verify each step.

Assembly Sequence Checklist:

Step | Task | Correct?
1 | Place case on work surface | [ ]
2 | Install plate grids with paste into each cell (correct plate count) | [ ]
3 | Install separators between plates | [ ]
4 | Install electrolyte containers into each cell | [ ]
5 | Install cell straps connecting cells in series | [ ]
6 | Install positive and negative terminal posts | [ ]
7 | Place top onto case | [ ]
8 | Secure with four hold-down screws | [ ]
9 | Attach TPU feet to bottom | [ ]

Grading:

- Correct order and orientation: 10 points
- Correct component quantities: 5 points

Part 3: Written Questions (15 points)

Answer each question in complete sentences.

1. How many positive plate grids and how many negative plate grids are in the entire battery? Why is the count different? (3 points)

Expected Answer: 6 positive grids and 12 negative grids. Each cell has one more negative plate than positive so that every positive plate has a negative plate on both sides for efficient current distribution.

2. Explain why the cells are connected in series rather than in parallel. What would happen to the voltage if they were connected in parallel? (3 points)

Expected Answer: Series connection adds voltages together (6 x 2.1V = 12.6V). If connected in parallel, the voltage would remain at 2.1V but the amperage capacity would increase. A vehicle's electrical system requires 12 volts, so series connection is necessary.

3. A customer asks: "What is the difference between a flooded battery and an AGM battery?" Explain the difference in terms a customer would understand. (3 points)

Expected Answer: A flooded battery has liquid acid inside that you can check and add water to — it has removable caps on top. An AGM battery has the acid soaked into fiberglass pads inside, so there's no liquid that can spill. AGM batteries are sealed and maintenance-free, but they cost more. Both do the same job of starting the engine.

4. What does CCA stand for, and why is it the most important rating for an automotive starting battery? (3 points)

Expected Answer: CCA stands for Cold Cranking Amps. It measures how much current the battery can deliver at 0°F for 30 seconds while staying above 7.2 volts. It's the most important rating because engines are hardest to start in cold weather — the oil is thicker and the battery's chemical reactions are slower, so you need to know the battery can deliver enough current when it matters most.

5. What would happen if the separators were removed from a battery? (3 points)

Expected Answer: Without separators, the positive and negative plates would touch each other and create a short circuit. The cell would discharge immediately, generate excessive heat, and could not produce voltage. The battery would be permanently damaged.

Submission

Students submit:

1. Completed Part 1 identification table
2. Instructor sign-off on Part 2 assembly
3. Written answers for Part 3

Rubric

Section | Points | Criteria
Part 1 — Identification | 20 | Correct name (1 pt) + correct function (1 pt) each
Part 2 — Assembly | 15 | Correct order (10 pts) + correct quantities (5 pts)
Part 3 — Written | 15 | Complete, accurate answers (3 pts each)
Total | 50 |