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P135703
Basic Hybrid and Electric Vehicle Safety
Course I.D.# C0904 Instructor: Jack Rosebro
er006
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Web Seminar I.D. #C0904
No part of this publication may be reproduced in any form, in an electronic retrieval system or otherwise, without the prior written permission of the publisher.
2014 SAE International
Positions and opinions advanced in this workbook are those of the author and not necessarily those of SAE. The author is solely responsible for the content of this workbook. A process is available by which technical advisors review the material for accuracy. For permission to publish this workbook in full or in part, contact SAE Professional Development.
Persons wishing to submit ideas for future programs or instructors to be considered for presentation or publication through SAE should send an outline and 300 word abstract to: e-Learning Manager, Professional Development, SAE
Printed in USA
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Basic Hybrid and Electric Vehicle SafetyI.D. #C0904
Duration: 1 Session
High-voltage, high-current energy storage systems and electrical circuits in many alternative-propulsion powertrains present unique challenges to the automotive industry. Care must betaken to minimize risk throughout the vehicle life cycle: to powertrain developers, assembly lineworkers, service technicians, vehicle occupants, and first responders. Significant risk to life, limb,and litigation can arise from a lack of understanding of the issues surrounding such vehicles.
This 120-minute web seminar reviews safety concerns and precautions related to high-voltage circuits present in hybrid, plug-in hybrid, electric, and fuel cell hybrid vehicles. HV circuits are discussed in general to provide an understanding of "where the risk lies". The effects of electrical current on the human body are summarized and existing protective measures, along with the standards that govern such measures, are described. Specific issues related to vehicle development, service, and operation are explained, along with onboard fault detection systems used to protect individuals from electrical injury.
Learning Objectives
By connecting with this web seminar, you will be able to:
x Describe component functions and locations in a typical high-voltage powertrain and theonboard safety systems associated with such components
x Explain the general effects of electric current on the human body
x Know which national and international safety standards apply to high-voltage vehiclecircuits
x Summarize HV safety working issues that may be present during a vehicle'sdevelopment, assembly, service, and operation
x Identify general issues associated with extrication of occupants from vehicles with high-voltage powertrains
Who Should Attend
Light and heavy duty engineers and technicians who work directly with high-voltage vehiclecircuits in hybrid, plug-in hybrid electric, and/or fuel cell hybrid vehicles, as well as componentsuppliers, safety officers and/or personnel who plan to develop high-voltage safety programs orprocedures, will benefit from this course.
Topical Outline
x General high-voltage electrical safety issues in vehicleso Issues with energy storage systemso Issues with motor controllers
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Topical Outline (continued)
o Issues with motor-generatorso Issues with DC-DC converterso Relationship between high-voltage (HV) bus and 12V buso Gasoline-electric hybrids (HEV)
x Electrical injuryo Effects of electrical energy on the human bodyo Electrical resistance of the human bodyo "Let-go" currento Common electrical accidents
x Industry protection against electrical injuryo Standards and regulations organizationso Personal protective equipment
x On-board vehicle protection against electrical injuryo Insulation and interlockso Ground-fault protection systemso Discharge and isolation circuits
x Powertrain development issueso Working with prototype battery packso Working in powertrain test cells
x Service and repair issueso Hazards associated with routine maintenanceo Hazards associated with HV component diagnosis and repairo General industry safety procedures
x Vehicle occupant and first responder issueso Protective measures for vehicle occupantso Hazards associated with vehicle occupant
Instructor: Jack Rosebro
Jack Rosebro has taught hybrid, plug-in hybrid, and electric vehicle technology toa wide variety of industry professionals for the past 1 0 years. He consults,writes, and conducts training seminars for Perfect Sky, Inc. in North America andEurope. Jack also writes on sustainable mobility for Green Car Congress. Hereceived his M.Sc from Blekinge Institute of Technology in Sweden.
.2 CEUs
Theinformation,representations,opinions,andrecommendationscontainedinthelecturesandhardcopymaterialarethoseoftheinstructor(s)andnotofSAEInternational.Thismaterialmaybecopyrightprotected.Nopartofthispublicationmaybereproducedinanyformwithouttheexpressed,writtenpermissionoftheinstructor(s).PleasenotethatSAEpolicyprohibitsanytypeofduplicationofthepresentationsorlearningmaterials.
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Bas
ic H
ybri
d a
nd
Elec
tric
Veh
icle
Saf
ety
Jack
Ros
ebro
, Per
fect
Sky
SAE Basic Hybrid and Electric Vehicle Safety Web Seminar
1
-
Lear
nin
g O
bje
ctiv
es
D
escr
ibe
com
pone
nt f
unct
ions
and
loca
tions
in a
typ
ical
hig
h-vo
ltage
po
wer
trai
n
D
escr
ibe
onbo
ard
safe
ty s
yste
ms
that
are
ass
ocia
ted
with
suc
h co
mpo
nent
s
Ex
plai
n ge
nera
l eff
ects
of el
ectr
ic c
urre
nt o
n th
e hu
man
bod
y
Kno
w w
hich
nat
iona
l and
inte
rnat
iona
l saf
ety
stan
dard
s ap
ply
to
high
-vol
tage
veh
icle
circu
its
Sum
mar
ize
HV s
afet
y w
orki
ng is
sues
tha
t m
ay b
e pr
esen
t du
ring
ve
hicl
e's
deve
lopm
ent,
ass
embl
y, s
ervi
ce,
and
oper
atio
n
Id
entif
y ge
nera
l iss
ues
asso
ciat
ed w
ith e
xtrica
tion
of o
ccup
ants
fro
m
vehi
cles
with
hig
h-vo
ltage
pow
ertr
ains
2
-
Gen
eric
ele
ctri
c d
rive
com
pon
ents
Inve
rter
Mo
tor
DC
AC
DC
-DC
con
vert
er
12
Vb
atte
ry
+
Bat
tery
pac
k
SAE Basic Hybrid and Electric Vehicle Safety Web Seminar
3
-
Laye
rs o
f el
ectr
ical
pro
tect
ion
1.H
V (
high
vol
tage
) ci
rcui
t is
olat
ion
from
cha
ssis
gro
und
2.H
V c
able
s an
d co
nnec
tors
are
ele
ctrica
lly in
sula
ted
3.Vol
tage
and
cur
rent
val
ues
are
outp
ut t
o di
agno
stic
dat
a
4.Po
wer
OFF
: in
vert
er is
dis
char
ged,
HV b
atte
ry p
ack
is is
olat
ed
5.Po
wer
OFF
, H
V s
ervi
ce:
serv
ice
plug
div
ides
HV b
atte
ry p
ack
6.Lo
w-v
olta
ge in
terloc
ks p
reve
nt H
V c
ircu
its f
rom
pow
erin
g up
7.H
V s
ervi
ce:
insu
latin
g gl
oves
and
HV-r
ated
met
ers
are
used
4
-
Ener
gy
stor
age
syst
ems
Bat
tery
pac
ks,
capa
cito
r pa
cks
SAE Basic Hybrid and Electric Vehicle Safety Web Seminar
5
-
Ener
gy
Sto
rag
e S
yste
ms
Le
ad-a
cid
batt
ery
pack
s (s
ome
olde
r hy
brid
s)
N
icke
l-m
etal
hyd
ride
(N
i-M
H),
pop
ular
for
hyb
rids
Li
thiu
m-i
on (
Li-i
on,
man
y va
riat
ions
use
d to
day)
Li
thiu
m-p
olym
er (
Li-P
o: C
hevr
olet
Vol
t, N
issa
n
Leaf
)
El
ectr
olyt
ic d
oubl
e la
yer
capa
cito
rs (
EDLC
)
6
-
Nic
kel-
met
al h
ydri
de
(NiM
H)
-Che
mis
try
of c
hoic
e fo
r m
any
hybr
ids
-El
ectr
olyt
e is
pot
assi
um h
ydro
xide
(KO
H)
-El
ectr
olyt
e is
aqu
eous
(wat
er-b
ased
)
-N
ot e
noug
h en
ergy
den
sity
for
PH
EVs,
EVs
-Can
be
neut
raliz
ed w
ith d
ilute
d bo
ric
acid
SAE Basic Hybrid and Electric Vehicle Safety Web Seminar
7
-
Cyl
ind
rica
l mod
ule
s: m
etal
cas
e
Tem
pera
ture
sen
sing
st
rip
Cel
l
Exam
ple
from
200
1-20
06 H
onda
Ins
ight
8
-
Pla
stic
cas
e w
ith m
etal
foil
Exam
ple
from
200
4-20
09 T
oyot
a Pr
ius
Ind
ivid
ual
cel
l (6
tot
al in
th
is m
odu
le)
SAE Basic Hybrid and Electric Vehicle Safety Web Seminar
9
-
Pris
mat
ic m
odul
es: p
last
ic c
ase
Tem
per
atu
re s
enso
r co
nn
ecto
r
Pre
ssu
re v
ent
Exam
ple
from
200
1 To
yota
Pr
ius
10
-
Pris
mat
ic m
odul
es: m
etal
cas
eEx
ampl
e fr
om 2
006-
2008
Toy
ota
Hig
hlan
der
Hyb
rid
Cle
ar p
last
ic in
sula
tes
con
du
ctiv
e m
etal
cas
e
Ind
ivid
ual
cel
l (8
tot
al in
th
is m
odu
le)
SAE Basic Hybrid and Electric Vehicle Safety Web Seminar
11
-
Cal
cula
tin
g s
tate
of
char
ge
-Cel
l SO
C c
anno
t be
cal
cula
ted
by v
olta
ge a
lone
-Cal
cula
ted
from
vol
tage
, cu
rren
t, a
nd t
empe
ratu
re
-H
EV p
acks
may
mon
itor
3 or
4 c
ell t
empe
ratu
res
-Vol
tage
is m
onito
red
in b
lock
s of
cel
ls (
~ 6
to
16)
-Cur
rent
is n
orm
ally
mea
sure
d at
the
pac
k le
vel
-Ex
cess
ive
variat
ion
in c
ell S
OC w
ill s
et a
cod
e
12
-
Hea
t tr
ansf
er in
bat
tery
cel
ls
Sou
rce:
N
atio
nal R
enew
able
Ene
rgy
Labo
rato
ry
Gen
erat
ion
I P
riu
s b
atte
ry m
odu
le h
eat
tran
sfer
Gen
erat
ion
II
Pri
us
bat
tery
mod
ule
hea
t tr
ansf
er
SAE Basic Hybrid and Electric Vehicle Safety Web Seminar
13
-
Tem
pera
ture
sen
sor
loca
tions
Exam
ple:
201
0 To
yota
Prius
. Sou
rce:
Toy
ota
Mot
or
Cor
pora
tion
14
-
Lith
ium
-ion
(Li
-ion
)
-Che
mis
try
of c
hoic
e fo
r pl
ug-i
n ve
hicl
es
-G
aini
ng p
opul
arity
for
con
vent
iona
l hyb
rids
-Li
-ion
ele
ctro
lyte
s ar
e orga
nic
andfla
mmab
le
-M
any
diff
eren
t ch
emis
trie
s ar
e us
ed
-Li
thiu
m-p
olym
er u
ses
sem
i-so
lid e
lect
roly
te
SAE Basic Hybrid and Electric Vehicle Safety Web Seminar
15
-
Exam
ple:
201
2 N
issa
n LE
AF.
Sou
rce:
Nis
san
Mot
or
Com
pany
Larg
e fo
rmat
Li-
ion
batt
ery
pack
s
16
-
Che
vrol
et V
olt
T-sh
aped
ba
tter
y pa
ck
Sou
rce:
Gen
eral
Mot
ors,
LLC
SAE Basic Hybrid and Electric Vehicle Safety Web Seminar
17
-
Mot
or c
ontr
olle
rs (
inve
rter
s)
18
-
Mot
or-g
ener
ator
s
SAE Basic Hybrid and Electric Vehicle Safety Web Seminar
19
-
DC
-DC
con
vert
ers
20
-
Pow
er u
p,
pow
er d
own
ESS is
olat
ion,
act
ive
and
pass
ive
disc
harg
e
SAE Basic Hybrid and Electric Vehicle Safety Web Seminar
21
-
Isol
atio
n re
lays
Sou
rce:
Dav
ide
dAnd
rea
22
-
On
boa
rd s
afet
y sy
stem
s
HV le
ak d
etec
tion,
ser
vice
plu
gs,
fusi
ng
SAE Basic Hybrid and Electric Vehicle Safety Web Seminar
23
-
Bat
tery
man
agem
ent
syst
ems
24
-
VAC
Gen
eric
HV
leak
det
ecti
on c
ircu
it
Bat
tery
EC
U
HV b
atte
ry n
egat
ive
AC s
ourc
e
HV
sys
tem
cir
cuit
Deg
rade
d H
V in
sula
tion
can
incr
ease
cap
acita
nce
betw
een
HV c
ircu
its
and
chas
sis
grou
nd
SAE Basic Hybrid and Electric Vehicle Safety Web Seminar
25
-
Gen
eric
HV
leak
det
ecti
on c
ircu
it
Deg
rade
d H
V in
sula
tion
can
incr
ease
cap
acita
nce
betw
een
HV c
ircu
its a
nd c
hass
is
grou
nd
HV+
HV
150
Vd
150
Vd
26
-
Serv
ice
plug
s an
d in
terlo
cks
SAE Basic Hybrid and Electric Vehicle Safety Web Seminar
27
-
Pu
rpos
e of
inte
rloc
k ci
rcu
its
Lo
w-v
olta
ge c
ircu
it th
at c
an d
isab
le h
igh-
volta
ge c
ircu
it
En
able
man
ual d
isab
ling
of b
atte
ry p
ack
with
ser
vice
plu
g
Pr
even
t ac
cide
ntal
sta
rt-u
p of
veh
icle
dur
ing
HV s
ervi
ce
N
otify
ECU
tha
t H
V c
ompo
nent
s m
ay b
e di
scon
nect
ed
Tr
igge
r D
TC a
nd F
F, w
hich
rec
ords
inte
rrup
tion
of H
V c
ircu
it
28
-
Sta
nd
ard
s,re
gu
lati
ons
ASTM
, IE
C,
OSH
A,
SAE
SAE Basic Hybrid and Electric Vehicle Safety Web Seminar
29
-
IEC
/A
STM
/O
SH
A s
tan
dar
ds
-IE
C g
over
ns E
urop
ean
safe
ty r
egul
atio
ns
-ASTM
set
s U
S s
afet
y st
anda
rds
-O
SH
A f
ollo
ws
ASTM
sta
ndar
ds
-Can
ada
gene
rally
fol
low
s ASTM
-Chi
na g
ener
ally
fol
low
s ASTM
-IE
C a
nd A
STM
cro
ss-r
efer
ence
eac
h ot
her
30
-
Tool
s an
d e
qu
ipm
ent
Met
er r
atin
gs,
insu
latio
n re
sist
ance
tes
ters
SAE Basic Hybrid and Electric Vehicle Safety Web Seminar
31
-
HV
glo
ves
and
acce
ssor
ies
32
-
Cla
ss 0
(zer
o) H
V in
sula
tin
g g
love
s ar
e ap
pro
pri
ate
for
hyb
rid
an
d E
V w
ork
Cla
ssV
olt
age
rati
ng
Co
lor
of
cuff
lab
el
0050
0Bei
ge
01
00
0R
ed
17,
500
Whi
te
217
,500
Yello
w
326
,500
Gre
en
430
,000
Ora
nge
SAE Basic Hybrid and Electric Vehicle Safety Web Seminar
33
-
Insu
latin
g gl
ove
volta
ge r
atin
g
34
-
Rol
l tes
t
SAE Basic Hybrid and Electric Vehicle Safety Web Seminar
35
-
CA
T-ra
ted
met
ers
and
lead
s
36
-
Insu
lati
on r
esis
tan
ce t
este
rsSAE Basic Hybrid and Electric Vehicle Safety Web Seminar
37
-
Insu
late
d t
ools
Sou
rce:
KTC
Too
ls
38
-
Wor
kin
g in
tes
t ce
lls
Esta
blis
hing
saf
ety
prot
ocol
s
SAE Basic Hybrid and Electric Vehicle Safety Web Seminar
39
-
Bat
tery
han
dlin
g
Esta
blis
hing
saf
ety
prot
ocol
s
40
-
HV
bat
tery
saf
ety
SAE Basic Hybrid and Electric Vehicle Safety Web Seminar
41
-
Veh
icle
des
ign
Prot
ectin
g fir
st r
espo
nder
s
42
-
Pro
tect
ing
fir
st r
esp
ond
ers
SAE Basic Hybrid and Electric Vehicle Safety Web Seminar
43
-
Elec
tric
al in
jury
El
ectr
ical
cur
rent
and
the
hum
an b
ody
El
ectr
ic a
rc
El
ectr
olyt
e le
akag
e
44
-
Mec
han
ical
inju
ry
Id
le-s
top
syst
ems
Pr
oxim
ity n
otifi
catio
n sy
stem
s
Fl
ywhe
el h
ybrids
H
ydra
ulic
hyb
rids
Com
pres
sed
air
hybr
ids
SAE Basic Hybrid and Electric Vehicle Safety Web Seminar
45
-
Flyw
hee
l ass
emb
ly
Sou
rce:
Por
sche
AG
46
-
Info
rmat
ion
des
ign
Prot
ectin
g se
rvic
e te
chni
cian
s
SAE Basic Hybrid and Electric Vehicle Safety Web Seminar
47
-
Wor
kin
g in
th
e fi
eld
48
-
Than
k yo
u f
or
atte
nd
ing
! Q
ues
tion
s?Ja
ck R
oseb
ro, P
erfe
ct S
ky
SAE Basic Hybrid and Electric Vehicle Safety Web Seminar
49
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