Basic Hybrid and

Electric Vehicle Safety

Course I.D.# C0904

Instructor: Jack Rosebro

er006
P135703

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

Basic Hybrid and Electric Vehicle Safety

I.D. #C0904
Duration: 1 Session
High-voltage, high-current energy storage systems and electrical circuits in many alternativepropulsion powertrains present unique challenges to the automotive industry. Care must be
taken to minimize risk throughout the vehicle life cycle: to powertrain developers, assembly line
workers, 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 highvoltage 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 the
onboard safety systems associated with such components

Explain the general effects of electric current on the human body

Know which national and international safety standards apply to high-voltage vehicle
circuits

Summarize HV safety working issues that may be present during a vehicle's

development, assembly, service, and operation

Identify general issues associated with extrication of occupants from vehicles with highvoltage powertrains

Who Should Attend

Light and heavy duty engineers and technicians who work directly with high-voltage vehicle
circuits in hybrid, plug-in hybrid electric, and/or fuel cell hybrid vehicles, as well as component
suppliers, safety officers and/or personnel who plan to develop high-voltage safety programs or
procedures, will benefit from this course.
Topical Outline
x

General high-voltage electrical safety issues in vehicles

o Issues with energy storage systems
o Issues with motor controllers

Topical Outline (continued)

o
o
o
o

Issues with motor-generators

Issues with DC-DC converters
Relationship between high-voltage (HV) bus and 12V bus
Gasoline-electric hybrids (HEV)

Electrical injury
o Effects of electrical energy on the human body
o Electrical resistance of the human body
o "Let-go" current
o Common electrical accidents

Industry protection against electrical injury

o Standards and regulations organizations
o Personal protective equipment

On-board vehicle protection against electrical injury

o Insulation and interlocks
o Ground-fault protection systems
o Discharge and isolation circuits

Powertrain development issues

o Working with prototype battery packs
o Working in powertrain test cells

Service and repair issues

o Hazards associated with routine maintenance
o Hazards associated with HV component diagnosis and repair
o General industry safety procedures

Vehicle occupant and first responder issues

o Protective measures for vehicle occupants
o Hazards associated with vehicle occupant

Instructor: Jack Rosebro

Jack Rosebro has taught hybrid, plug-in hybrid, and electric vehicle technology to
a 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 and
Europe. Jack also writes on sustainable mobility for Green Car Congress. He
received his M.Sc from Blekinge Institute of Technology in Sweden.
.2 CEUs
Theinformation,representations,opinions,andrecommendationscontainedinthelecturesandhardcopymaterialare
thoseoftheinstructor(s)andnotofSAEInternational.Thismaterialmaybecopyrightprotected.Nopartofthis
publicationmaybereproducedinanyformwithouttheexpressed,writtenpermissionoftheinstructor(s).

PleasenotethatSAEpolicyprohibitsanytypeofduplicationofthepresentationsorlearningmaterials.

Jack Rosebro, Perfect Sky

Basic Hybrid and

Electric Vehicle Safety

SAE Basic Hybrid and Electric Vehicle Safety Web Seminar

Identify general issues associated with extrication of occupants from

vehicles with high-voltage powertrains

Summarize HV safety working issues that may be present during

vehicle's development, assembly, service, and operation

Know which national and international safety standards apply to

high-voltage vehicle circuits

Explain general effects of electric current on the human body

Describe onboard safety systems that are associated with such

components

Describe component functions and locations in a typical high-voltage

powertrain

Learning Objectives

Battery pack

DC

+
12V
battery

DC-DC converter

Inverter

AC

Motor

Generic electric drive components

SAE Basic Hybrid and Electric Vehicle Safety Web Seminar

7. HV service: insulating gloves and HV-rated meters are used

6. Low-voltage interlocks prevent HV circuits from powering up

5. Power OFF, HV service: service plug divides HV battery pack

4. Power OFF: inverter is discharged, HV battery pack is isolated

3. Voltage and current values are output to diagnostic data

2. HV cables and connectors are electrically insulated

1. HV (high voltage) circuit isolation from chassis ground

Layers of electrical protection

Battery packs, capacitor packs

Energy storage systems

SAE Basic Hybrid and Electric Vehicle Safety Web Seminar

Electrolytic double layer capacitors (EDLC)

Leaf)

Lithium-polymer (Li-Po: Chevrolet Volt, Nissan

Lithium-ion (Li-ion, many variations used today)

Nickel-metal hydride (Ni-MH), popular for hybrids

Lead-acid battery packs (some older hybrids)

Energy Storage Systems

- Can be neutralized with diluted boric acid

- Not enough energy density for PHEVs, EVs

- Electrolyte is aqueous (water-based)

- Electrolyte is potassium hydroxide (KOH)

- Chemistry of choice for many hybrids

Nickel-metal hydride (NiMH)

SAE Basic Hybrid and Electric Vehicle Safety Web Seminar

Temperature sensing
strip

Example from 2001-2006 Honda Insight

Cylindrical modules: metal case

Cell

Example from 2004-2009 Toyota

Prius

Plastic case with metal foil

Individual cell (6 total in this module)

SAE Basic Hybrid and Electric Vehicle Safety Web Seminar

10

Example from 2001 Toyota

Prius

Prismatic modules: plastic case

Temperature sensor connector

Pressure vent

11

Example from 2006-2008 Toyota Highlander

Hybrid

Prismatic modules: metal case

Clear plastic insulates conductive metal case

Individual cell (8 total in this module)

SAE Basic Hybrid and Electric Vehicle Safety Web Seminar

12

- Excessive variation in cell SOC will set a code

- Current is normally measured at the pack level

- Voltage is monitored in blocks of cells (~ 6 to 16)

- HEV packs may monitor 3 or 4 cell temperatures

- Calculated from voltage, current, and temperature

- Cell SOC cannot be calculated by voltage alone

Calculating state of charge

13

Source: National Renewable Energy Laboratory

Generation II Prius battery module heat transfer

Generation I Prius battery module heat transfer

Heat transfer in battery cells

SAE Basic Hybrid and Electric Vehicle Safety Web Seminar

14

Example: 2010 Toyota Prius. Source: Toyota Motor

Corporation

Temperature sensor locations

15

- Lithium-polymer uses semi-solid electrolyte

- Many different chemistries are used

- Li-ion electrolytes are organic and flammable

- Gaining popularity for conventional hybrids

- Chemistry of choice for plug-in vehicles

Lithium-ion (Li-ion)

SAE Basic Hybrid and Electric Vehicle Safety Web Seminar

16

Example: 2012 Nissan LEAF. Source: Nissan Motor

Company

Large format Li-ion battery packs

Source: General Motors, LLC

Chevrolet Volt T-shaped

battery pack

SAE Basic Hybrid and Electric Vehicle Safety Web Seminar

17

18

Motor controllers (inverters)

Motor-generators

SAE Basic Hybrid and Electric Vehicle Safety Web Seminar

19

20

DC-DC converters

ESS isolation, active and passive discharge

Power up, power down

SAE Basic Hybrid and Electric Vehicle Safety Web Seminar

21

22

Source: Davide dAndrea

Isolation relays

HV leak detection, service plugs, fusing

Onboard safety
systems

SAE Basic Hybrid and Electric Vehicle Safety Web Seminar

23

24

Battery management systems

25

HV battery negative

HV system circuit

Degraded HV insulation can increase capacitance between HV circuits

and chassis ground

AC

AC source

Battery ECU

Generic HV leak detection circuit

SAE Basic Hybrid and Electric Vehicle Safety Web Seminar

HV+

150 Vd

150 Vd

HV

Generic HV leak detection circuit

Degraded HV insulation can increase capacitance between HV circuits and chassis

ground

26

Service plugs and interlocks

SAE Basic Hybrid and Electric Vehicle Safety Web Seminar

27

28

Trigger DTC and FF, which records interruption of HV circuit

Notify ECU that HV components may be disconnected

Prevent accidental start-up of vehicle during HV service

Enable manual disabling of battery pack with service plug

Low-voltage circuit that can disable high-voltage circuit

Purpose of interlock circuits

Standards,
regulations

ASTM, IEC, OSHA, SAE

SAE Basic Hybrid and Electric Vehicle Safety Web Seminar

29

30

- IEC and ASTM cross-reference each other

- China generally follows ASTM

- Canada generally follows ASTM

- OSHA follows ASTM standards

- ASTM sets US safety standards

- IEC governs European safety regulations

IEC/ASTM/OSHA standards

Meter ratings, insulation resistance testers

Tools and equipment

SAE Basic Hybrid and Electric Vehicle Safety Web Seminar

31

32

HV gloves and accessories

Voltage rating

500
1000
7,500
17,500
26,500
30,000

Class

00

33

Orange

Green

Yellow

White

Red

Beige

Color of cuff label

Class 0 (zero) HV insulating gloves are

appropriate for hybrid and EV work

SAE Basic Hybrid and Electric Vehicle Safety Web Seminar

34

Insulating glove voltage rating

Roll test

SAE Basic Hybrid and Electric Vehicle Safety Web Seminar

35

36

CAT-rated meters and leads

Insulation resistance testers

SAE Basic Hybrid and Electric Vehicle Safety Web Seminar

37

38

Insulated tools

Source: KTC Tools

Establishing safety protocols

Working in test cells

SAE Basic Hybrid and Electric Vehicle Safety Web Seminar

39

40

Establishing safety protocols

Battery handling

HV battery safety

SAE Basic Hybrid and Electric Vehicle Safety Web Seminar

41

42

Protecting first responders

Vehicle design

Protecting first responders

SAE Basic Hybrid and Electric Vehicle Safety Web Seminar

43

44

Electrolyte leakage

Electric arc

Electrical current and the human body

Electrical injury

45

Compressed air hybrids

Hydraulic hybrids

Flywheel hybrids

Proximity notification systems

Idle-stop systems

Mechanical injury

SAE Basic Hybrid and Electric Vehicle Safety Web Seminar

46

Source: Porsche AG

Flywheel assembly

Protecting service technicians

Information design

SAE Basic Hybrid and Electric Vehicle Safety Web Seminar

47

48

Working in the field

49

Jack Rosebro, Perfect Sky

Thank you for

attending! Questions?

SAE Basic Hybrid and Electric Vehicle Safety Web Seminar

PROFESSIONAL
DEVELOPMENT
SEMINARS
One to three-day, live, instructor led courses that
address relevant technologies, engineering tools, and
management techniques
training.sae.org/seminars

e-LEARNING
Training in technical, business and standards related
topics delivered via your desktop or laptop.
training.sae.org/elearning

ENGINEERING ACADEMIES
Intensive classroom course sessions for engineers who
need to quickly develop or expand their knowledge of a
particular technology.
training.sae.org/academies

CORPORATE LEARNING SOLUTIONS

Customized, cost-effective on-site training addressing the
specic needs of your organization.
training.sae.org/corplearning