C0904_091814[1].pdf

P135703

Basic Hybrid and Electric Vehicle Safety

Course I.D.# C0904 Instructor: Jack Rosebro

er006

Web Seminar I.D. #C0904

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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

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.

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


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


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


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)


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)


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


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


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


17

Mot

or c

ontr

olle

rs (

inve

rter

s)

18

Mot

or-g

ener

ator

s


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


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


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


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


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


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


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


33

Insu

latin

g gl

ove

volta

ge r

atin

g

34

Rol

l tes

t


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


39

Bat

tery

han

dlin

g

Esta

blis

hing

saf

ety

prot

ocol

s

40

HV

bat

tery

saf

ety


41

Veh

icle

des

ign

Prot

ectin

g fir

st r

espo

nder

s

42

Pro

tect

ing

fir

st r

esp

ond

ers


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


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


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


49

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C0904_091814[1].pdf

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