Welcome

Electric vehicle HV- Safety- Training

1
1. Day
Introduction and Training background
Organisation of safety and health for electrical work (including Five
safety rules)
Electrical hazards, including measures for protection against
electric shock and fault arcs
Practical - Demonstrating, using and wearing all safety kit and PPE
Break
Basic electrical knowledge and measurement technology
Motor and motor controlling technology
Lunch
Practical - Instruments and measuring technology for current, 2. Day
voltage, resistance First Aid
Introducing HV system on electric vehicles, such as battery Practical - The usage of Testing equipment, such as two-pole voltage tester,
management system, driving motor, motor controller, DC/DC equal potential tester
inverter, HV power battery pack Charging system on electric-vehicle
Break Written Examination
Practical - Introducing HV system on electric vehicle Break
Practical - Execute Five safety rules on electric vehicle Practical - measurement exercises on electric vehicle, such as insulation
resistance, equal potential
Lunch
Practical - Troubleshooting on electric vehicle
Break
Practical Examination

2
 • （1）Electrical Hazards
• （2）Safety Working Instruction and PPE
• （3）Electrical Engineering: the Basics
• （4）Measurement Technology
• （5）Electric Vehicle Introduction
• （6）Electric Motors
• （7）Traction Battery
• （8）High voltage protection measures on EV
• （9）Technical and managerial responsibility with regard to electrical hazards
• （10）First Aid

3
 Training Introduction

4
Definition- High Voltage

A high voltage system carries more than

1000 Volts between conductors and 600
Volts between conductors and ground.
By using transformers, the voltage of the
power can be stepped up to a high
voltage so that the power may be distributed
over long distances at low currents and
hence low losses.

5
 Training background——Does electric vehicle belong to HV?

Lithium- ion Battery Porsche

Lithium-ion battery
800 V
Electric energy 93,4,kwh
396 Pouch Cell

▪ Source: Porsche

6
Training background

Definitions

High voltage(HV):
In the automotive sector, particularly in hybrid
and fuel cell technology and on electric
vehicles, high voltage comprises voltages
>60V and ≤1500V DC
and
>25V and ≤1000V AC

7
Automobile Regulations, Laws, Guidelines samples……………..

• The Electricity at Work Regulations 1989

• The Health and Safety at Work Act 1974
• The Management of Health and Safety at Work
Regulations 1999
• The Provision and Use of Work Equipment Regulations
1998
• The Control of Substances Hazardous to Health (COSHH)
Regulations 2002
• The Dangerous Substances and Explosive Atmospheres
(DSEAR) Regulations 2002
• …………….. Etc.

8
 Training standard

▪ Based on the employee’s work environment and job

Training stage responsibilities, the training is divided into four levels .

✓ Non-electrical person required working on a vehicle or

installations containing HV systems
Level 1:Non-electrical work ✓ Test driver
✓ Oil change, wheel change
✓ Other mechanical work

✓ Work on HV systems and components in the non-live state

Level 2:Electrical work in
✓ Could join in Level 2 training without Level 1 certification
the non-live state
✓ R&D staff, testers, engineers and technicians

✓ Successful completion of level 2 training is a

prerequisite
Level 3: Live work on HV ✓ troubleshooting
system and work in the ✓ Work on power battery live
proximity of exposed ✓ Replacing parts live
live parts

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 Training standard

Training for work on series production vehicles- Non-electrical

work, the topics of this instruction must include:

1) operation of vehicles and the associated equipment

2) Performance of general tasks which do not require isolation of the HV system
3) Location and marking of the HV components and lines in and on the vehicle
4) Performance of all mechanical tasks on the vehicle (but: don’t touch orange!)
5) Isolation of the HV system as specified by the manufacturer, serving as an
additional safety measure to prevent unauthorised and inadvertent use
6) Appointment of the individual to be consulted in the event of uncertainty (such as
the expert in HV systems)
7) Impermissible work on the vehicle
8) Organisational procedure for electrical work that is performed under the control
and supervision of a skilled electrical person for HV systems

12
 Training standard

Training for work on series production vehicles——

Electrical work in the non-live state, the topics of this
instruction must include:

1) Basic electric knowledge

2) Electrical hazards and first aid
3) Measures for protection against electric shock and against fault arcs
4) Organisation of safety and health for electrical work
5) Specialist and man-management responsibility
6) Employee qualifications in the area of electrical engineering
7) Use of HV systems in the vehicle

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 1.Electrical hazards

Effects of electrical current on the body

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 1.Electrical hazards
Regulations for working with electric current

Electrical hazards
On the HV system when the voltage between the live components is greater than 25V AC or
60V DC and the short-circuit where work is being performed exceeds the value of 3mA AC
or 12mA DC.

Consequently, work on electrical installations may be carried out by qualified

electricians only.
(Accident prevention regulations: Electrical installations and equipment (BGV A3))

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 1.Electrical hazards

How to discover the current?

Our sensory organs will not tell

us: “Attention of the high
voltage”.

We often ignore those dangers

we cannot sense. So we often
lack the awareness of the
danger of high voltage.

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 1.Electrical hazards

- Electric shock
Current effect
（electric shock） - Burn
- Death

External burns
- Melted material
Arc/Spark - Ultraviolet radiation
- Toxic gas

Secondary damage
- Fall from high altitude
（stress reaction or - Fire
panic reaction） - bomb

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 1.Electrical hazards

Hazards of electric current – effects on the human body

Thermal effect
 Internal and external burns
 Protein coagulation (above 42°C)
 Bursting blood cells

Chemical effect
 Decomposition of the body fluid

Irritant effect
 Irritant effect on nerves, muscles and heart.

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 1.Electrical hazards

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 1.Electrical hazards

Electric Accident The pictures may cause you discomfort.

Watching carefully

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 1.Electrical hazards
The pictures may cause you discomfort.
Electric Accident
Watching carefully

21
 1.Electrical hazards

Electrical trauma

Many people survive electrical trauma only to

find a host of injuries including loss of
consciousness, seizures, aphasia, visual
disturbances, headaches, tinnitus, paresis, and
memory disturbances.
Even without visible burns, electric shock
survivors may be faced with long-term
muscular pain and discomfort, fatigue,
headache, problems with pesuripheral nerve
conduction and sensation, inadequate balance
and coordination, among other symptoms.
Electrical injury can lead to problems with
neurocognitive function, affecting speed of
mental processing, attention, concentration,
and memory.

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 1.Electrical hazards
How about working on EV?
Touch different parts with different electric voltage through conductive
tools or human body.

• Current flowing through the

body always choose the path
with lowest resistance .
• The current flowing between
two hands will also flow
through important organs, such
as the heart.

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 1.Electrical hazards
Limit of Let-go Fibrillation
perceptibility current threshold
10000
No effect on body
5000
Fatal electric 1
2000
Exposure time [ms]

shock
1000
probable No Hazardous
500 2 Effects
1 2 3 4
200
Risk of
100 Triggering characteristic
3 ventricular
of residual current circuit
50
breaker Fibrillation
20

10 4 Ventricular Fibrillation
0.1 0.2 0.5 1 2 5 10 20 50 100 20 500 100 mA 5000
0 0

Current [mA] through the human body

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 1.Electrical hazards

Body resistance Current strength,

Current path
(estimate) while power is 330V.

hand— hand 1000 Ω 330 mA

Hand— foot 1000 Ω 330 mA

hand—two feet 750 Ω 440mA

Hand—chest 450 Ω 733 mA

Note
Dry skin is generally considered to have a very high resistance
at low voltage, about 100KΩ; when the skin is sweaty, it is
about 1KΩ; when the skin is injured, it is about 800Ω; when the
voltage is in the 500-1000 volts, the resistance will drop to 1000
Ω.

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 1.Electrical hazards

Summary
Hazard of electric shock：
Electric shock could cause severe effect on human body, burns,
respiratory and heartbeat interruption, permanent physical injury and
death.

The lethality of an electric shock is dependent on several factors:

► current strength
► current duration
► contact voltage strength
► current path（worse case through the heart）
► current frequency

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 2. Safety working instruction and PPE

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 2. Safety working instruction and PPE

Five Safety Rules

Prior to starting work Electrical work may only be started when protective
measures have been taken against electric shock, short-
• Isolate circuits and fault arcs.

• Safeguard Against State 2 :It is not permitted to work on live active parts of
electrical installations or equipment under any
Reconnection circumstances.
• Verify non-live state A voltage-free condition must therefore be established
• Earth and Short Circuit before starting work and ensured for the duration of the
work.
• Shroud or safeguard adjacent
parts
You must follow manufacturer instructions when work
on EV!

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 2. Safety working instruction and PPE
Four Stages or Processes of Work to Consider

• Before

• During

• Interrupted

• After

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 2. Safety working instruction and PPE

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 2. Safety working instruction and PPE
Personal protective equipment

What is personal protective equipment (PPE)?

• Depending on the work and intended application:

• Approved high-voltage gloves

• When working on parts with sharp edges, wear leather gloves
over the high-voltage gloves. The wearing leather gloves alone
is not permitted!
• Safety goggles or face mask
• Only close-fitting work clothes are approved for this field of
work. With some employers, even fire-retardant working clothes
are prescribed!
• Only specifically designed working shoes or electricians' shoes
are permitted!

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 2. Safety working instruction and PPE
Measuring tools（DGUV 200-006 standard）

1) Measurement tools approved by vehicle manufacturer;

2) The two-pole voltage tester according to DIN VDE 0682-401, and has been
verified for the circuit under test; the insulation level must be higher than the
voltage of measured circuit .

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 2. Safety working instruction and PPE
Safety working instruction——Five safety rules

Five Safety Rules

Prior to starting work
• Isolate
• Safeguard Against Reconnection
• Verify non-live state
• Earth and Short Circuit
• Shroud or safeguard adjacent parts

Working with the protective equipment

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 2. Safety working instruction and PPE

On-site security
separate the specific area for HV electric vehicle

Regional regulations：
• Only allow EV project related
personnel to enter, set up
the EV project’s specific
label, to distinguish.
• Do not allow unauthorised
people to enter the area to
operate the EV

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 2. Safety working instruction and PPE

Five safety rule (universal instruction)

1. Switch off the low voltage power

• Ignition off
• Disconnect 12 Volt battery.
• Wait at least ten minutes

You must follow manufacturer

instructions when work on EV!

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 2. Safety working instruction and PPE

Five safety rule (universal instruction)

2. Check PPE and Tools

• Gloves
• Matting or Work
Shoes
• Multimeter
• Safety Rescue Hook
• Eye Protection

You must follow manufacturer

instructions when work on EV!

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 2. Safety working instruction and PPE

Five safety rule (universal instruction)

3. Switch off the high

voltage power

• Unlock the Service

switch.
• Remove the service
switch = disconnect
voltage power supply;

You must follow manufacturer

instructions when work on EV!

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 2. Safety working instruction and PPE

Five safety rule (universal instruction)

4. Check absence of
high voltage by
measuring at the
specific location
specified in the
technical documents.
This is different for
each manufacturer.

Two-pole
voltage tester “–” to “+”,
You must follow manufacturer
“-” to “chassis”, instructions when work on EV!
“+” to “chassis”
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 2. Safety working instruction and PPE

Five safety rule (universal instruction)

5. Safeguard against reconnection

• Remove the ignition key and prevent
unauthorised access to it.
• Store the service plug against unauthorised
access/safeguard the main battery switch against
reconnection, for example by means of a lock or
lockable shroud.
• Place warning signs to show vehicle status and
prevent unwanted connection. You must follow manufacturer
instructions when work on EV!

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 2. Safety working instruction and PPE

6. Reconnection After Work

• Check all Terminals tightened to specified Torque
• Check and confirm no damage to high voltage
wires or terminals
• Test insulation resistance between each high
voltage terminal and vehicle body
• Reverse Disconnection process to reconnect the
high voltage system

You must follow manufacturer

instructions when work on EV!

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 3. Electrical engineering: The basics

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 3. Electrical engineering: The basics

What’s is electricity?

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 3. Electrical engineering: The basics

What’s the definition of electric current?

Electric current describes the directional movement of

electric charges
Electricity always flows in a closed circuit

Technical flow direction from plus (+) to minus (-)

+ -
▪ Corresponds to the historical flow direction

Physical flow direction from minus (-) to plus (+)

▪ Corresponds to the real electron flow direction

+ -

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 3. Electrical engineering: The basics
Strength of current?

In a circuit, the quantity of electric charges through a cross section of the

conductor per unit time. The formula symbol for current is “I”. The basic unit of
current is “A”
How about voltage?
+5 V 𝜑1 Points with different charges have a
potential relative to a reference point (e.g.
earth)
An electric voltage (difference in potential)
exists between two points with different
charges, e.g. the plus and minus terminal of a
+2 V 𝜑2
battery
The formula symbol for voltage is “V”. The
basic unit of voltage is “V”

44
 3. Electrical engineering: The basics
What‘s DC?
Definition of DC and AC
[U / V]
DC voltage DC ("Direct Current")
DC is the unidirectional flow of electric charge. Direct
current is produced by sources such as batteries.
[t / h]
AC voltage AC ("Alternating Current")
What‘s AC? AC is an electric current in which the flow of electric
charge periodically reverses direction.
[+U]

[t]

[-U]

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 3. Electrical engineering: The basics

Definition of resistance

The resistance has the property of limiting the current in a circuit

In electronics, resistance plays a very important role
Every component has a resistance that influences the voltages and
currents in a circuit
The resistance is measured in Ohms (Ω), named after the
German physicist Georg Simon Ohm (1789-1854)
The formula symbol for resistance is R

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 3. Electrical engineering: The basics

What’s PTC and NTC resistor?

R [Ω] PTC resistor

A positive temperature coefficient (PTC) refers to materials that
experience an increase in electrical resistance when their
temperature is raised.
A negative temperature coefficient (NTC) refers to materials that
NTC resistor experience a decrease in electrical resistance when their
temperature is raised.

T [°C]

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 3. Electrical engineering: The basics

Bulb Switch Battery Transistor

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 3. Electrical engineering: The basics

Ohm's Law
V The relationship between the electric current, voltage and
resistance is described by Ohm's Law
R I ▪ Precondition: Constant ambient conditions

How large is the current in the circuit illustrated?

R = 100 Ω
V
V=R*I R=
I

V 12 V
I= = = 0.12 A
R 100 Ω

V = 12 V

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 3. Electrical engineering: The basics
Power’s law(P)
P
I V P=V*I

P (Power)

R
(Resistance)

I V
(Current) （Voltage)

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 3. Electrical engineering: The basics

Electrical Work’s law：

W = P * t =V * I * t

1kwh =1000W*3600S= 3.6*106 J

P t

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 3. Electrical engineering: The basics

Kirchhoff's first law of the electric circuit

At the central node of an electrical network, the

sum of the incoming currents is equal to the sum
of the outgoing currents.

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 3. Electrical engineering: The basics

Connection of batteries in series

In a series connection, the total voltage

VBatt is divided into the part-voltages
I2 I3
A A V1 + V2 + V3
The current I is equal to I1 is equal to I2
V1 V2 V3
V V V is equal to I3
I1
A A
I = I1 = I2 = I3
V I1+2+3
VBatt = V1 + V2+ V3

53
 3. Electrical engineering: The basics

Connection of batteries in parallel

I3
A
V3
V In a parallel connection, the
I2 total current I is divided into
A
V2 the part-currents I1 + I2 + I3
V The voltage VBatt is equal to
I1 V1 is equal to V2 is equal to V3
A
V1 I= I1 + I2 + I3
V I1+2+3
VBatt = V1 = V2 = V3
A
V

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 4. Measurement technology

55
 4. Measurement technology

Consumer Measuring in the circuit

Vbatt = Total battery voltage

V1 = Voltage at the consumer
V I1 = Current in the supply line
I1 V1
A A I2 = Current in the return line
I2
VBatt
V
How about the resistance?

Ohms Law: R = V/I

Voltage source
V=12
I=4
R=?

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 4. Measurement technology

In a series connection:
In a series connection, the total voltage VBatt is divided into the part-voltages
V1 + V 2 + V 3
The current I1+2 is equal to I1 is equal to I2 is equal to I3
I1+2 = I1 = I2 = I3
VBatt = V1 + V2+ V3 Consumer
I2 I3
A A

V1 V2 V3
V V V
I1
A VBatt A
V I1=2=3

Voltage source

57
 4. Measurement technology

In a parallel connection:
Consumer
In a series connection, the total current I1+2+3 is divided into the
I3
A part-currents I1 + I2 + I3
V3 The voltage VBatt is equal to V1 is equal to V2 is equal to V3
V
I2 I1+2+3 = I1 + I2 + I3
A VBatt = V1 = V2 = V3
V2
V
I1
A
V1
V I1+2+3
A
V
VBatt

Voltage source

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 4. Measurement technology

What are the most frequent measurement errors?

• Wrong choice of measuring method

• Measuring range set incorrectly
• Current measurements not performed in series
• Voltage measurements not performed in parallel to the component

▪ Resistance measurements not performed with the component voltage-free

▪ Resistance measurements not performed with the component disconnected
▪ Changing measuring method and range with cables connected(possible arcing, and burning the
switch contacts, especially high voltage and high current)

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 5. Electric vehicle introduction

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 5. Electric vehicle introduction
Why eMobility?
Comparison of efficiency – electric motor vs. internal combustion engine

100%

75%

Efficiency
50%
92%

25%
44%
33%

0%
Elektromotor
Electrical motor Dieselmotor
Diesel engine Gasoline engine
Ottomotor

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 5. Electric vehicle introduction
Why eMobility?

ICE V
extraction distribution ICE

The efficiencies show what

percentage of the supplied primary
energy is converted into motion

Fuel Cell EV
electrolysis distribution Fuel Cell

charging &
distribution elec. engine Battery EV
battery

Source: BMU, Erneuerbar mobil

62
 5. Electric vehicle introduction
Why eMobility?
Conventional braking

During braking with the conventional hydraulic or pneumatic friction brake, the kinetic energy (motion
energy) of the vehicle is converted into heat energy

63
 5. Electric vehicle introduction
Why eMobility?
Recovery braking

During recovery braking, the vehicle is braked partly or completely by a generator

 The electrical energy generated here and stored in a battery can then be used to
drive the vehicle

You must follow manufacturer

instructions when working on
EV braking systems!

64
 5. Electric vehicle introduction

Classification- pure electric vehicle, central motor

Pure electric vehicle

possesses one or more
motors serving as drive
units.
This kind of vehicle is
driven purely by electrical
energy, without the need
for a combustion engine or
a hybrid concept.

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 5. Electric vehicle introduction

Classification——pure electric vehicle, wheel–hub drive

The vehicle is powered by four electric wheel-hub
motors integrated respectively into the four wheels.

• A wheel hub motor has many advantages:

• It increases the amount of available space
because the former engine compartment can be
used for storage. It reduce the transmission
elements, such as gearbox, drive shafts, since
the motor is now located directly on the wheel.
• This improves the efficiency, which amounts to
an average of 93%.
• The hub motor makes it possible to control each
wheel independently. This creates a lot of new
development opportunities going far beyond the
possibilities of classic ESPs.。
• The different weight distribution also has a
positive effect, distributed motors result in a low
centre of gravity.

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 5. Electric vehicle introduction

Classification——hybrid electric vehicle

BEV

Micro Mild Strong hybrid:

hybrid hybrid Serial, parallel, mixture mode,
Mechanical peak output of electric motor
3 kW 5 kW 12 kW 30 kW 60 kW 400 kW

Battery-side system voltage

14 V 42 V 144 V 288 V 750 V

Start / Stop Recovery Electric starting Electric

boosting Additional functions Driving

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 5. Electric vehicle introduction
Parallel hybrid

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 5. Electric vehicle introduction
Serial-hybrid (range extender)

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 5. Electric vehicle introduction

Hybrid electric vehicle——why low fuel consumption?

Inadequate supply HV battery

Store residual
energy
Braking recovery

Engine stop

Engine stop Engine work

Start and accelerate Drive Brake and recovery

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 5. Electric vehicle introduction
Traction battery
Traction battery is the power source for electric vehicle. There are different kind of
battery, such as Lithium-ion Battery, Ni-MH Battery and Lead-acid Battery.

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 5. Electric vehicle introduction
Vehicle Layouts

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 5. Electric vehicle introduction
Vehicle Layouts

Source: Volkswagen Media

73
 5. Electric vehicle introduction

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 5. Electric vehicle introduction

Maintenance switch（or service switch）

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 5. Electric vehicle introduction

DC to AC Inverter

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 5. Electric vehicle introduction

DC to AC Inverter

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 5. Electric vehicle introduction
DC to DC Converter

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 5. Electric vehicle introduction

Driving motor and motor controller

Powertrain

Motor
controller

Rated output power：75kW

Maximum output torque：450N·M

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 5. Electric vehicle introduction

Air conditioning system——are there any HV components？

Rear evaporator
And expansion valve
Front evaporator

Solenoid valve Expansion valve

Heat exchanger
Compressor

Condenser

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 5. Electric vehicle introduction

Charging system——are there any HV components？

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 5. Electric vehicle introduction

Charging port
GB

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 5. Electric vehicle introduction

HV Cables including Charging Cables

It is important to inspect high voltage components
during any service or repair operation, including the
charging cables (pictured here)

High voltage cables and components should

undergo a visual check for damage and correct
routing as well as security

Pay attention to the following:

• The high voltage cables must not reveal any
external damage
• Insulation of high voltage cables must not be
defective or damaged
• Unusual deformations of cables

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 5. Electric vehicle introduction
Fuel cell electric vehicle

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 6. Electric Motors

85
 6. Electric Motors

Electricity、Magnetic field、Torque
André-Marie Ampère Michael Faraday

Electricity Magnetic field Magnetic field Electricity

Electricity
Torque
Magnetic field

86
 6. Electric Motors
What ‘s the magnetic field like for permanent magnet?

N S

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 6. Electric Motors
What’s the magnetic field like generated by an electrified wire?

Ampere Rule, or Right hand rule

✓ Electrified straight wire: hold the power straight wire with the right hand,
and the direction of the thumb point to the current direction; then the
direction of the four fingers is the direction of the magnetic field;
✓ Electrified solenoid: hold the solenoid with the right hand, and the
direction of the four fingers follows the direction of current, then the thumb
points to the N pole of the magnetic field.
Electrified straight wire Electrified solenoid

88
 6. Electric Motors
How to generate induced electromotive force by magnetic field?

Electromagnetic induction law:

✓ Generate induced electromotive force due to the variation of magnetic flux;
✓ Conductive part of a closed circuit in the magnetic field, the conductor will
produce current if cutting through magnetic induction line, this phenomenon is
called electromagnetic induction.

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 6. Electric Motors
What’s the direction of induced current?

Lenz’s law: The induced current, generated by the changes of the

magnetic flux, will resist the magnetic flux changes, that is, the magnetic
field of induced current always hinder the change of magnetic flux which
induce the current.

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 6. Electric Motors
Ampere force, Lorentz force?
Left hand rule
✓ Ampere force: stretch the left hand, and the thumb and the other fingers are
perpendicular, in the same plane; let the magnetic lines go into the palm of the
hand, and the fingers point to the direction of the current, so the direction of the
thumb is the direction of ampere force.
✓ Lorentz force: stretch the left hand, let the magnetic lines go into the palm of the
hand, and the fingers point to the moving direction of positive charge, then the direction of
thumb is the direction of Lorentz force.

+q

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 6. Electric Motors

The 3-phase AC motor

3-phase AC motors are driven by a 3-phase alternating

current
The curve of the voltages can be seen in the left-hand
figure

A 3-phase AC motor consists of

a stator and a rotor

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 6. Electric Motors

Symmetrical three-phase systems: Star/delta circuits

Neutral point

At any time, the sum of the three currents of a

symmetrical 3-phase system is zero

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 6. Electric Motors

H bridge:
▪ 4 switches per winding strand
Winding strand

B6 bridge:
▪ 6 switches for 3 winding strands

The costs for the power electronics are dictated

by the costs for the switches, which in turn are
dependent on the product of the voltage to be
blocked and the current to be transmitted.
Stator winding

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 6. Electric Motors

AC synchronous motors

Design:
• DC excited winding or permanent
magnets in the rotor
• Winding, which usually has three
strands in the stator
• Cyclic changing of the current direction
in the stator strands by power supply
from an AC grid or an electronic
inverter

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 6. Electric Motors

AC synchronous motors

• In the synchronous motor, the rotary field generated by the stator winding tows
the rotor along.
• The speed of a synchronous motor is always the "synchronous speed".

n1 = 60f / p

Where f = Frequency of the stator currents

p = number of pole pairs

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 6. Electric Motors
AC synchronous motors
Permanently excited synchronous motor
Advantages:
• Permanent magnet excited
• Very high full-load efficiency
• High power factor
• Very high torque density
• No slip loss
• No brushes required
• Flexible arrangement of the magnets

Disadvantages:
• Considerable losses at low load
• More laborious assembly/disassembly
• Costs of the permanent magnets
• Service life
• No de-energisation possible in the event of a fault

97
 6. Electric Motors
Induction motors (asynchronous motors)

Design:
• Stator winding usually with three strands
as with synchronous motors
• Usually with squirrel-cage winding in the
rotor
• Cyclic changing of the current direction
in the stator strands by means of a
power supply from an AC grid or an
electronic inverter
• Stator and rotor cores are cyclically
magnetised and demagnetised and
must be laminated

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 6. Electric Motors
Induction motors (asynchronous motors)

• The speed of induction motors has a slip s in relation to the synchronous

speed.
• Definition:

Bar

Shaft
where n = Rotor speed
n1 = 60f/p = Synchronous speed
Short-circuit ring
Squirrel-cage rotor
(shown without laminated core)

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 6. Electric Motors
Induction motors (asynchronous motors)

Advantages:
• Very sturdy
• Good torque density and efficiency
• No permanent magnets or brushes required
• Low production costs

Disadvantages:
• Speed is roughly proportional to the power supply
frequency; speed setting requires a frequency
converter
• Higher inverter power than with synchronous motors
• Efficiency and torque density lower
than synchronous motor

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 6. Electric Motors
Motor concepts in eMobility
Outlook – Which motor type will establish itself for eMobility?

Permanently excited synchronous Asynchronous motor (ASM)?

motor (PSM)?

High power density

Magnetic and thermal power limitation
Only thermal power limitation
Magnet material expensive (rare earths)
High efficiency with medium and high High rotor mass and inertia
loads
High efficiency at part-load
Passive braking
Excitation controllable
Relevance for safe towing!
Intrinsically safety for towing

101
6. Electric Motors

102
 7. Traction battery

103
 7. Traction battery
Battery parameter
Battery performance parameter
（sample）

Cell capacity 200Ah

Nominal voltage of cell 3.2V

Number of cell 96

battery connection Series

Total voltage 307V

Total power 57kWh

Charging voltage 200V ~ 400V

Weight of package 800KG

Driving range 250~300km

104
 7. Traction battery

Lithium-ion battery

105
 7. Traction battery

Lithium-ion battery

Nissan LEAF Tesla

106
 7. Traction battery

Lithium-ion battery

107
 7. Traction battery
Battery accumulators – terms
U

• Nominal voltage
✓ Actual voltage available
✓ Depends on the materials used

• Cut-off voltage
✓ Lower voltage limit to which the battery may be discharged
without being damaged

• Internal resistance of a cell

✓ Electrical resistance of the battery
✓ Depends on the materials used
✓ Objective  Lowest possible internal resistance in order to reduce
losses

108
 7. Traction battery
Battery accumulators – terms

• Capacity of a cell
✓ means how much electricity the battery could discharge under certain
conditions(temperature, discharging current, cut-off voltage and so on),
the unit normally is Ah.
✓ C=I * t
✓ Parallel connection of cells increases the capacity
• SOC
✓ State of charging
✓ In practice not all the energy is used in order to protect the cell
capacity
battery
100%

SOC = 100%
Used
capacit
y
SOC = 0%

109
 7. Traction battery
Battery accumulators – terms

Relative discharging/charging current

▪ Describes the current to discharge/charge the cell related to its nominal capacity.
▪ The unit is C; 1C is the current necessary to discharge/charge the cell within one hour
▪ Example: Cell with 500 mAh  1C = 500 mA, 2C = 1000 mA, 10C = 5000 mA

▪ Energy density
- The amount of energy could be stored by unit weight of the battery, the unit is Wh/kg,
the energy density is determined by the battery material properties.

▪ Power density
- The energy output rate for unit weight of the battery when discharging, the unit is
W/kg, the power density is determined by the battery material properties.

110
 7. Traction battery
What characteristics are needed for batteries on electric vehicles?

• Safety
• High Energy Density
• High Power Density
• Cycle Stability
• Costs

111
 7. Traction battery
Ragone plot

112
 7. Traction battery

Lithium-ion battery

Lithium series battery

Lithium battery Lithium-ion battery

Polymer lithium-ion battery Liquid lithium-ion battery

113
 7. Traction battery

Lithium-ion battery
Sample
18650 20700
18mm 20mm 18650 lithium-ion battery

Nominal voltage：3.6~3.7

Cut-off voltage：2.5~2.75
65mm 70mm

Capacity：1200~3300mAh

114
 7. Traction battery

Lithium-ion battery
Positive electrode material
Lithium transition metal oxides, such as LiCoO2,LiMn2O4, Li(NiCoMn)O2,
LiFePO4.

Negative electrode material

Carbon materials, cheap, non-toxic, such as nature graphite, synthetic
graphite, carbon fibre. Nature graphite has a low embedding potential,
excellent embedding – de-embedding performance, and is good
negative electrode material for lithium-ion batteries. The theoretical
formula for the formation of lithium and carbon is generally LiC6.

115
 7. Traction battery
Lithium-ion battery
Positive electrode
(aluminium foil with e.g.
lithium iron phosphate)
Active material, e.g. Active material, e.g.
lithium metal oxide lithium graphite
Current
conductor
Current (copper)
conductor
Positive electrode

electrode
Negative
(aluminium)
Separator

Separator Electrolyte

Film pouch Negative electrode (copper

foil with w.g. graphite)

Conductors must be chemically stable and inexpensive

Active materials determine cell voltage and cell designation!

116
 7. Traction battery
Lithium-ion battery

An exchange of lithium ions takes place

during charging and discharging
▪ "Rocking chair" or "swing" system

Lithium ions are deposited in the active

materials

Carbon (Graphite) Non-aqueous solution

Metal (Cobalt)
Lithium charging process
Oxygen discharging process

117
 7. Traction battery

▪ Traction battery package on EV

118
 7. Traction battery

What influences the ageing behaviour of Li ion batteries?

■ Temperature

■ Cycles

■ Charge/discharge rate

■ Calendrical ageing

■ Depth of discharge © Fraunhofer IFAM

119
 7. Traction battery
Range of electric vehicles with Li-ions

Maximum range according to

Nissan Leaf 24 kWh, 140 km manufacturer

Mitsubishi i-MiEV 16 kWh, 150 km

BMW i3 21.6 kWh, 190 km

Renault Zoe 22 kWh, 210 km

Tesla Model S 85 kWh, 480 km

120
 7. Traction battery
Range comparison of Li-ion vehicles according to manufacturers'
specifications and at winter temperatures

Maximum range according to

Nissan Leaf manufacturer

Tested range in winter

Mitsubishi i-MiEV

BMW i3

Renault Zoe

Tesla Model S

121
 7. Traction battery
Lithium ion battery: Ageing behaviour

Temperature (during discharge)

▪ Typical Li ion cells are designed for a working range of 0 – 40°C
▪ Significant capacity losses at lower temperatures (< 0 °C)
▪ Cell damage at very high temperatures (> 40°C)
▪ Cause  Irreversible increase in the internal resistance due to a
change in the conductivity of the electrolyte
▪ Special Li ion high-temperature cells available for applications from -
50°C to + 60°C (e.g. from SAFT).
 but only with low discharge currents (C/5)!

122
 7. Traction battery
Lithium ion battery: Ageing behaviour

Number of cycles
▪ Phase 1: Forming phase = Cell becomes stabilised (approx. first 50 cycles)
▪ Phase 2: Operating phase = Cell has practically no loss of capacity (approx. 50
– 2000 cycles)
▪ Phase 3: Rapid ageing = Capacity losses per cycle (> 2000 cycles)

Phase 1 Phase 2 Phase 3

80%
Capacity

Number of cycles

123
 7. Traction battery
Lithium ion battery: Ageing behaviour

Calendrical ageing
▪ Occurs particularly with fully charged batteries
▪ Self-discharge and irreversible loss of capacity due to ageing

Deep discharge cycles

▪ result in capacity losses due to irreversible ageing processes at the
electrodes

High charge/discharge currents

▪ Thermal loading due to high currents results in ageing of the cell

124
 7. Traction battery
Lithium ion battery: Advantages and disadvantages:

Advantages
▪ No memory effect
▪ High cell voltage of over 3 V
▪ High power and energy density

Disadvantages
▪ Sensitivity to temperature
▪ Sensitivity to deep discharging and overcharging (BMS necessary)
▪ Fire and explosion hazard

125
 8. High voltage protection measures on EV

126
 8. High voltage protection measures on EV

ECE-R100

127
 8. High voltage protection measures on EV
Identifying High Voltage Vehicles

Identification will include:

• Badging
• Instrument Pack
• Charge Point
• Orange Cables

128
 8. High voltage protection measures on EV
Identifying High Voltage Vehicles

• Full Electric - EV
• Parallel Hybrid - HEV
• Plug In Hybrid - PHEV
• Series Hybrid - IMA
• Range Extender -
PHEV
• Fuel Cell Vehicle - FCV

129
 Resources

130
131
 8. High voltage protection measures on EV

Residual current circuit breaker

132
 8. High voltage protection measures on EV

Electric shock on EV:

• “Direct contact shock”: suffer electric shock by direct contact

with live parts of electrical equipment and electrical circuit. The
impact of direct electric shock may be the most serious, body
current is always far greater than the limit stage causing
ventricular fibrillation.

• “indirect contact shock” : suffer electric shock by contacting

exposed conductive enclosure that is electrified because of
faults, insulation damage.

133
 8. High voltage protection measures on EV
Basic protection

Basic protection
Protection against direct contact

Basic protection under normal conditions

Active parts must be completely covered by an

Basic insulation of active parts
insulation (cable sheath) that can only be
removed by destruction

Active parts must be sheathed or covered,

protection class at least IPXXB or IP2X

134
 8. High voltage protection measures on EV
Basic protection
A Class II or double insulation
A Class II or double insulated electrical appliance is one
which has been designed in such a way that it does not
require a safety connection to electrical earth (ground).
The basic requirement is that no single failure can result in
dangerous voltage becoming exposed so that it might
cause an electric shock and that this is achieved without
relying on an earthed metal casing. This is usually achieved
at least in part by having two layers of insulating material
surrounding live parts or by using reinforced insulation.

135
 8. High voltage protection measures on EV
Basic protection

Basic protection- Marking

Cables for high voltage buses which are not
located within enclosures shall be identified by
having an outer covering with the colour orange.

On or near the power battery package and other

HV components, need to have the warning labels.

136
 8. High voltage protection measures on EV
Basic protection

Anti-intrusion connector

The shielding layer for HV cables.

137
 8. High voltage protection measures on EV
Basic protection
IP Protective
As electrical equipment and systems can be operated
under various conditions and environmental influences, a
definition has been drawn up according to types of
protection in order to ensure optimum adaptation to the
operating conditions and operational safety

A distinction is made between

▪ Personal and foreign body protection

▪ Water protection

▪ Further types of protection are also given

138
 8. High voltage protection measures on EV
Conductor HV Cabling
Insulation The centre of a typical power cable contains the conductor
This has a very low resistance and rated for continuous operation
Surrounding the conductor is a layer of insulation that prevents
leakage of high electrical energy
The next layer of the cable is the shielding
This is braided to protect other electronic systems from
Electromagnetic Interference (EMI) created by the high energy
passing through the cables
The final layer is the sheath that protects the cable from extreme
temperatures, dust and fluids

Braided
Shield Sheath

139
 8. High voltage protection measures on EV
HV Cabling

Other components such as electric air con compressors may

have 3 phase electricity carried in a single cable

All connections are insulated and waterproof, are

mechanically strong and very low resistance

140
 8. High voltage protection measures on EV

Pre-protection

Protection measures for HV safety

and against function fail :
Collision protection, HV interlock,
Cover opening protection, Function
interlock, Reverse polarity protection
Reverse polarity
and so on. protection

Function
interlock
Collision
protection HV Cover opening
interlock protection

141
 5. Electric vehicle introduction
Pilot Line

142
 8. High voltage protection measures on EV
Pre-protection
HVIL

Service switch
Function： Driving motor
• ► safety circuit is a ring circuit,
which is controlled by 12V HV battery
power grid. Motor controller
• ► HV connector can not be
unplugged until the safety circuit
A/C compressor
is disconnected.
• ► HV system will be cut off if
safety circuit is disconnected.

143
 8. High voltage protection measures on EV
Power grids – IT system

Insulation resistance must be monitored！

144
9.Technical and managerial responsibility with regard to electrical hazards

145
 Technical and managerial responsibility with regard to electrical
hazards
Technical and managerial responsibility

What are technical and managerial responsibilities

Obligations of employers and employees

Definition of personnel groups

▪ Electric Vehicle Informed Person

▪ Electric Vehicle Competent Person

▪ Electric Vehicle Authorised Person

▪ Electric Vehicle Senior Authorised Person

146
Technical and managerial responsibility with regard to electrical
hazards
Technical and managerial responsibility

Senior Authorised

Authorised
Competent

Informed

(Start of training)
0 1 2 3 Level

147
Technical and managerial responsibility with regard to electrical
hazards
Technical and managerial responsibility

General obligations of the employer

• Implement measures to ensure the safety and health of employees

• Organisation of the company

• Assessment of working conditions

• Make selections to assign responsibility for duties

148
 Technical and managerial responsibility with regard to electrical
hazards Technical and managerial responsibility

Important obligations of the employer in the workshop / automotive industry

• Carry out risk assessments

• Provide tools and equipment
• Train qualified staff or select according to their qualification
• Organise training measures
• Draw up working instructions
• Instruct employees
• Organise tests
• Monitor implemented measures

149
Technical and managerial responsibility with regard to electrical
hazards
Technical and managerial responsibility

What are technical and managerial responsibilities?

This term is used to define the levels of responsibility from top to bottom. That
means in practice: Who is responsible for what and when?

▪ For the employee:

 Who can I ask for working instructions or information?

 From who can I get my protective equipment?

150
Technical and managerial responsibility with regard to electrical
hazards Technical and managerial responsibility

General obligations of the employee

• Follow personal and general safety instructions

• Handle the personal protective equipment carefully and use it for its intended purpose only

• Pay attention to your own safety and the safety of colleagues

• Avoid accidents at work and errors

• Document work

• Report all accidents at work

151
Technical and managerial responsibility with regard to electrical
hazards
Definition of personnel groups

Electric Vehicle Informed Person

is trained by at least an electrically trained person

▪ Carries out work without high-voltage hazards

▪ Is instructed about the necessary protective measures
▪ May work only under the supervision of an electrically trained person on high-
voltage vehicles
▪ Suitable for sales team, parts staff, drivers, valeters etc.

152
Technical and managerial responsibility with regard to electrical
hazards
Definition of personnel groups
Electric Vehicle Competent Person

is trained by at least an Authorised Person for specified activities

on:

▪ Authorised work and activities on ‘non-live’ vehicles

▪ Cannot work on ‘live’ high voltage components or vehicles
▪ Possible hazards
▪ Is instructed about the necessary protective measures
▪ Electrical work may only be carried out under the supervision and instruction
of an authorised person

153
Technical and managerial responsibility with regard to electrical
hazards
Definition of personnel groups
Electric Vehicle Authorised Person

is trained for specified activities on:

▪ “Live” vehicles
▪ Is able to make a vehicle safe for work and re-instate afterwards.
▪ Is instructed about the necessary protective measures
▪ Can delegate and supervise high voltage work by ‘competent’ persons

154
Technical and managerial responsibility with regard to electrical
hazards
Definition of personnel groups

Electric Vehicle Senior Authorised Person

They are by virtue of their professional training, know-how, experience and their
knowledge of the relevant regulations for the specified activities, is able to assess the
assigned work and to recognise possible dangers. Is the person-in-charge for high voltage
vehicle assessment, diagnosis and specialist repairs to vehicles that are in the ‘live state
• Duties could be:
• Vehicle assessment
• Fault Diagnosis
• Specialist Repairs
• Working on vehicle in ‘live’ state
155
 9.Technical and managerial responsibility with regard to electrical hazards

Summary

Working on electrical components

When work is carried out on electrical components in motor
vehicles, the statutory requirements must be observed

Electrical installations and equipment may only be installed,

modified or repaired under the instruction and supervision
of a qualified electrician

156
 10.First aid for electrical hazards

157
 10.First aid for electrical hazards

Rescue chain
When an electric shock occurs, be sure to Calm down

. Pay attention to
your own safety/
Rescue the people
Make an EMERGENCY CALL
from electric shock Hospital
/ immediate measures

急救电话
120
First aid measures Emergency services by doctors

158
 10.First aid for electrical hazards

There are two very important steps as following if you haven’t been
professionally trained(CPR):

Disconnect the Make an EMERGENCY CALL

power supply

Immediately implement the above rescue measures!

Only in this way, there is chance to rescue people from electric shock.

159
 10.First aid for electrical hazards
Cut off the power

Danger if touching charged objects.

➢ Cut off the power：
disconnect the circuit breaker, or pull out the plug

When these measures can not be implemented immediately：

➢ First of all, insulate yourself(such as dry wood), and prohibit
touching directly.
➢ Use insulating objects(such as dry wood) to separate the victim
from the charged objects.

Note: it is necessary to protect against falling if the victim is on high place.

160
 10.First aid for electrical hazards

The rescue hook

To pull an accident victim out of the danger zone

without endangering your own safety

161
 10.First aid for electrical hazards

If the injured can talk, rescue people can take measures

as following:
▪ If the person suffering electric shock has no loss of consciousness, you
should try to keep him calm down, remove the fear, don’t let him to
move around, so as not to increase the burden on the heart, and finally
let doctor to check.
▪ Cool the burned wound if possible and cover with a sterile, lint-free
towel!
▪ Even if he or she refuses, the injured must go to see a doctor (latent
characteristics)

162
 10.First aid for electrical hazards

If the injured can not dialogue, rescue people can take

measures as following:
▪ The most important thing is to confirm the life of the injured, such as

pulse and breathing!

▪ Make an emergency call immediately!

▪ Take necessary emergency care before the arrival of the doctor, e.g.

perform first aid if the victim is no longer breathing or pulse(if you have

received CPR training)

163
 10.First aid for electrical hazards

Chances of success with resuscitation

125

100

75
[%]

50

25

0
0 1 2 3 4 5 6 7 8 9 10 11 12
Zeit [min]
time

164
 10.First aid for electrical hazards

■ Attend first aid

courses!
■ Practice makes
perfect!

165
 10.First aid for electrical hazards

Electrolyte damage rescue of Lithium-ion

battery
• Very strong alkaline and VERY harmful
• Colourless and odourless
• Dilute Boric Acid or Vinegar
• Once neutralised the spill is harmless
and can be washed away

166
 10.First aid for electrical hazards
Electrolyte damage rescue of Lithium-ion battery
• Always wear Alkaline resistant gloves and a full face mask

• Prepare red litmus paper and neutraliser

• Apply red litmus paper to leaking solution and check colour change

• If it changes to Blue, pour on neutraliser

• Test again with litmus paper and repeat process until litmus paper does not change colour

• When litmus paper doesn’t change colour the spill is harmless and can be washed or wiped away

• Well ventilated area and stand upwind

• Remove ANY clothing that comes into contact with electrolyte IMMEDIATELY

• If skin comes into contact with electrolyte wash with large volumes of water IMMEDIATELY

• If electrolyte gets into eyes, into mouth, or into a cut in skin, wash with large volumes of water
IMMEDIATELY and urgently seek medical attention.
167
 What do I do with
this???

168
 10.First aid for electrical hazards

169
 10.First aid for electrical hazards
Fire fighting

When electrical equipment or lines are on fire, cut off the

power as soon as possible to prevent electric shock.

• Do not use water or foam extinguisher, especially on oil fires.

• Water (in large quantities) can be used to extinguish an EV fire
• Carbon dioxide or dry powder extinguisher should be used.

Note: if inhaling the smoke of high voltage electrical fire, move outside
for fresh air as soon as possible, and go to a doctor.

170
 10.First aid for
electrical hazards

Fire fighting

171
 10.First aid for
electrical hazards

Fire fighting

172
 10.First aid for
electrical hazards

Fire fighting

173
 10.First aid for
electrical hazards

Fire fighting

174
 10.First aid for electrical hazards
Fire fighting
• A vehicle Fire Blanket can also contain fire

Note: if inhaling the smoke of high voltage electrical fire, move outside
for fresh air as soon as possible, and go to a doctor.

175
 10.First aid for electrical hazards
Fire fighting

176
 10.First aid for electrical hazards
Fire fighting

177
 What do I do with
this???

178
 EINTAC

• PPE and Tools

• Discount Code
TS10 for 10% off
all orders
• https://eintac.com

Version 3 179
 Resources

180
 Resources

❖ NFPA (nfpa.org)

181
 Resources

182
 Case Studies
MG ZS
We followed the manufacturer
guidelines which are:
• Turn off ignition switch and wait for
5 minutes
• Disconnect 12v battery negative
terminal
• Raise vehicle on lift and remove
manual service disconnect cover
plate
• Remove manual service disconnect
from high voltage battery pack -
note: This is part of the interlock
system, it is not a physical
disconnect plug in the manner of a
Prius or similar.

183
 Case Studies
MG ZS

184
 Case Studies
MG ZS

MG do not specify any

further checks to confirm
that the system has been
shut down so we removed
the HV battery cable and
tested with a Cat III 1000v
multimeter to confirm zero
voltage.

185
 Case Studies
Toyota Prius

■ A series of temp
sensors are used in
all battery packs
■ Air flow keeps the
temperature under
120º F (49º C)
■ 146º F (63º C) is the
limit before cell
damage

186
 Case Studies

■ Inlet on Prius II -III

■ Blower and air ducts
connect to the pack
■ Toyota Vent Filter

187
 Case Studies
Prius IV

188
 Case Studies
Prius IV

189
 Case Studies
Battery Disconnection

■ MSD is required to
expose HV Battery
Terminals

190
 Case Studies

2 Modules=
One V block

V1 A Module
191
 Scan Tool Data - Gen 1 Prius

Delta SOC is normal at

20%. All other Toyotas
Delta SOC is “0”

Min / Max V Block Voltage + / - 0.2 volts

192
 Case Studies

More screen captures HV Battery

193
 Case Studies
Delta SOC is one indicator of NiMH
Battery Health

Delta 20% Normal on

Gen I Prius
All Other Prius 0%
Higher is HV Bat issue
Lower is Software /
Electronic issues

194
 Case Studies

0.2 volts is
Toyota
specification
when the Module
has 6 cells

0.3-0.5 volt difference low/high is OK

0.6 to 1.0 expected life of HV pack unknown
1.1 volts and higher .. Codes will set
195
 Case Studies

196
 Case Studies

197
 Case Studies
Overcharged. Easy Diagnosis

198
 Case Studies

■ The internet is full

of “how to” with
HV Battery repairs
■ Careful here

199
 Case Studies
The $9,317.53 Fuse

■ All Hybrid Ford

Escape / Mariner
■ You also get a FREE
HV battery pack

200
 Case Studies
Volt/Ampera Battery Pack … Special Handling

201
 Case Studies

Volt/Ampera Battery Pack … Special Handling

■ The HV battery of the
Volt/Ampera is a sealed
unit.
■ This prevents
contaminants from
entering the battery.
■ This also contains any
materials that may leak
from the battery in the
event of failures.

202
 Case Studies

Volt/Ampera Battery Pack … Special Handling

■ Install the perimeter
fasteners after
cleaning them and
coating them with
butyl tape.
■ Tighten these
fasteners to 9 Nm

203
 Case Studies

Volt/Ampera Battery Pack … Special Handling

■ GM specifies special tool
EL-50812 to block off the
connectors of the battery
pack while smoke testing.
■ These are all the
connectors at the front of
the battery pack that will
allow smoke to go
through them.

204
 Case Studies

Volt/Ampera Battery Pack … Special Handling

■ Place a small
pin hole into
the vents
■ The “vents”
can breathe
out but not in Vents

205
 Case Studies

Volt/Ampera Battery Pack … Special Handling

206
 Case Studies

Volt/Ampera Battery Pack … Special Handling

■ When the smoke starts to

exit the small pin-hole, it
can be assumed that
smoke has filled the entire
battery containment area.
■ Cover this hole and check
for leaks.

207
 Case Studies

Volt/Ampera Battery Pack … Special Handling

■ Our only leaks

found were the
poorly made
plugs.
■ The battery can
now be reinstalled
into the vehicle.

208
 Case Studies

Nissan Leaf
2011- 2012

209
 Case Studies

B
Look Closely for
Polarity… A & B

A Only 2011-2012

210
 Case Studies One 3 Phase DC-DC
Drive Motor / Converter
Gear Junction
Reduction / Block Nissan Leaf
Differential 2011- 2012
Inverter

Battery Pack Orange Energy

Transfer Cables
211
 Case Studies

Nissan Leaf
2011- 2012

Floor Board
designed to hold
48 Li-ion modules

212
 Case Studies

Nissan Leaf
2011- 2012

Battery Pack
drops out
from the
bottom

213
 Case Studies

214
 Case Studies

Nissan Leaf
2011- 2012

HV Connector 12V Connector

215
 Case Studies

Nissan Leaf
2013-2017

3 Connections
on Front

216
 Case Studies
Nissan Leaf
Do NOT remove this clip 2013-2017
This Clip
■ There is an “O” ring
behind it
■ The cover is sealed
■ It will push back
through
■ 12 volt connection

217
 Case Studies

Nissan Leaf
2018-onwards

218
 Case Studies
Nissan Leaf
2018-onwards

219
 Case Studies
Nissan Leaf
2018-onwards

48 Modules

4 cells per
Module

LEAF Modules
NO cooling .. Really!

220
221