With the increasing number of electric and hybrid vehicles on the road, major automobile enterprises are committed to making electric vehicle technology transparent to enhance customer acceptance of products. The battery system is the core component of electric and hybrid vehicles, but relevant technical personnel lack sufficient understanding of its safety. Due to the special nature of electricity, it is difficult to judge possible electrical hazards through senses such as vision or hearing. This course will systematically introduce the risks of high-voltage battery systems and related component structures. Understanding these risks can help learners improve risk awareness and find response solutions, while also helping improve personal injury protection awareness, reduce product risks, and better identify treatment solutions for potential risks.

• Understand basic electrical safety knowledge
• Identify risk response methods for battery systems
• Develop safety procedures to manage risks

• Automotive and battery engineers, battery system integration engineers, battery test engineers, safety system engineers, electrical engineers and structural engineers in electric and hybrid vehicle development projects. Personnel engaged in specification formulation, design, R&D, testing and planning of high-voltage batteries for electric and hybrid vehicles can also benefit from this course.

• Basic parameters and terminology
• Circuits and networks: DC circuits, AC circuits
• Electrical hazards: harm of current to the human body, protection against voltage and current
• IP protection levels and protection classes on vehicles
• Distribution network types, electrical insulation systems
• Five safety principles
• Testing of high-voltage systems and components
• First aid basics
• Hybrid basics: power, torque, voltage and current
• Series hybrid, parallel hybrid, series-parallel hybrid
• Components of electric and hybrid vehicles
• Energy storage systems: rechargeable batteries, capacitors
• Motors: DC motors, synchronous motors and asynchronous motors
• Transmission devices
• Power electronic components: semiconductor components, rectifiers and converters, on-board power supplies, control electronics
• Fossil fuels and hybrid power: energy comparison chart, efficiency and weight, fuel cost
• Role of batteries: internal combustion engine and electric system, energy and power
• Vehicle lifecycle expectations, product liability
• Battery development cycle: system considerations, electrochemical selection
• Safety: advance planning of safety tests, thermal runaway
• Arrangement configuration (series, parallel)
• Range estimation (hybrid and electric)
• Battery selection analysis and calculation
• Battery pack design considerations
• Failure modes
• Vehicle trends: plug-in hybrid, battery electric, fuel cell hybrid
• Battery trends: battery warranty, battery recycling
• Avoiding internal hazards during handling
• Impact of environmental deviations
• MSDS material safety data sheet
• Special tools, ground faults
• Handling of failed or scrapped batteries