Basic Hybrid and Electric Vehicle Safety     

Part of the SAE Hybrid Fundamentals Web Seminar Series

I.D.# C0904Printable Description
Duration: 2 Hours
  Delivered in
Show Session Dates
September 28, 2017 (1 Session ) - Live Online

High-voltage, high-current energy storage systems and electrical circuits in many current and future alternative-propulsion powertrains present unique challenges to the automotive industry. Care must be taken to minimize risk to all who come into contact with the vehicle throughout its development and life cycle, including powertrain developers, assembly line workers, service technicians, vehicle occupants, and first responders. Significant risk to life and limb can arise from technical issues surrounding these 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. A general understanding of electrical and mechanical engineering is helpful, but is not required.

This course has been approved by the Accreditation Commission for Traffic Accident Reconstruction (ACTAR) for 2 Continuing Education Units (CEUs). Upon completion of this e-seminar, accredited reconstructionists should contact ACTAR, 800-809-3818, to request CEUs. As an ACTAR approved course, the fee for CEUs is reduced to $5.00.

Learning Objectives
By participating in this web seminar, you will be able to:

  • Describe component functions and locations in a typical high-voltage powertrain as well as 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 high-voltage 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

  • General high-voltage electrical safety issues in vehicles
    • Issues with energy storage systems
    • Issues with motor controllers
    • Issues with motor-generators
    • Issues with DC-DC converters
    • Relationship between high-voltage (HV) bus and 12V bus
    • Gasoline-electric hybrids (HEV)
  • Electrical injury
    • Effects of electrical energy on the human body
    • Electrical resistance of the human body
    • "Let-go" current
    • Common electrical accidents
  • Industry protection against electrical injury
    • Standards and regulations organizations
    • Personal protective equipment
  • On-board vehicle protection against electrical injury
    • Insulation and insulation breakdown
    • Fusing and interlocks
    • Ground-fault protection systems
    • Discharge and isolation circuits
  • Powertrain development issues
    • Working with prototype battery packs
    • Working in powertrain test cells
  • Service and repair issues
    • Hazards associated with routine maintenance
    • Hazards associated with HV component diagnosis and repair
    • General industry safety procedures
  • Vehicle occupant and first responder issues
    • Protective measures for vehicle occupants
    • Hazards associated with vehicle occupant

Instructor(s): Jack Rosebro
Jack RosebroJack Rosebro has taught hybrid, plug-in hybrid, and electric vehicle technology to a wide variety of automotive industry professionals for the past ten years. Since 2006, he has developed and delivered curriculum for Perfect Sky, Inc. throughout the US and Canada. He also consults to community colleges that are integrating hybrid and electric vehicle technology into their curricula. Jack writes about hybrid technology, regulatory issues, and sustainable mobility for Green Car Congress, and is a frequent speaker at industry conferences. Previously, Jack developed and taught courses on hybrid and electric vehicles, air/fuel systems, OBD-II self-diagnostic systems, and emission control systems. He received his M.Sc. in Engineering from Blekinge Institute of Technology in Sweden.

Registration Information
Registration for this live web seminar is available on a per-person basis, similar to purchasing a seat in a classroom. Participants attend an online session from work or home; anywhere with a PC with internet access (at least 56K) and a telephone. The fee includes one connection to the conference calls (toll free telephone number provided for U.S. and select countries*) and assigned personal ID number; one connection to SAE's online training center (via WebEx); and access to a secure course in the SAE Learning Center that contains the presentations, class session recordings, supplemental materials, and assignments.

Registrations will be accepted until 5:00 p.m. the day before the start of the web seminar, but early registration is encouraged to allow for pre-course set-up and instructions.

*Global toll-free telephone numbers are provided for many countries outside the U.S., but are limited to those on the WebEx call-in toll-free number list. Check here to see if your country has a global call-in toll free telephone number for this web seminar. If your country is not listed, you may still connect using the US/Canada Call-in toll number or Voice over Internet Protocol (VoIP).

Although WebEx Training Manager will automatically launch when you join the web seminar, you or your system administrator are encouraged to download the plug-in in advance to help ensure successful setup. Click here, then follow the onscreen instructions.

NOTE: The course presentation will be recorded and made available for 30 days to those who register by the deadline.

Multiple Seat Discount - 50% off more than one!

  1. Register for this Web Seminar at the appropriate list or member price and enjoy a 50% discount off the list price of the other hybrid web seminars in this series (includes Introduction to Hybrid Powertrains; Plug-In Hybrids: Opportunities And Challenges; Hybrid And Electric Vehicles: Current Production, Future Strategies.).


  2. Register one individual at the appropriate list or member price, then register as many additional employees at half off the list price. To receive the discount, register all individuals at the same time or mention the confirmation number for the first registrant. The offer is good for only the same web seminar series and dates. All registrants will receive a personal account and opportunity for CEUs.
Registration by phone with SAE Customer Service is required to take advantage of these discounts.

Can't attend on the date/time above? The presentation will be recorded and made available for 30 days to those who are registered, regardless of availability for the live session. If you still need to cancel, transfer to a future offering, or designate a substitute, a full refund is issued if you notify SAE at least 14 days prior to the web seminar start date. If less than 14 days prior, please contact SAE Customer Service to discuss options*. NOTE: SAE reserves the right to cancel web seminar and cannot be held responsible for related costs incurred by registrants other than the registration fee.

*Cancellation penalties may apply.

Fees: $270.00 ; SAE Members: $216.00 - $243.00

.2 CEUs
You must complete all course contact hours and successfully pass the learning assessment to obtain CEUs.


"This was probably the best web instruction I've received, and better than many live sessions I've done. Jack Rosebro was spot on and very up to date and informative."
John W. Froeb
Senior Product Design Engineer
Parker SSD Drives Division

"Great means of accomplishing training while travel budgets are tight. I didn't seem to lose much by being physically absent. (I) liked the session times and ability to stay home to learn the material."
Jason Osborn
Design Engineer, Sr
Bobcat Company

"Web Seminars are a very user friendly, convenient, low cost educational alternative."
Bob Pheiffer
Business Development
InterRegs - International Regulations

To register, click Register button at the top of this page and submit the online form, or contact SAE Customer Service at 1-877-606-7323 (724/776-4970 outside the U.S. and Canada) or at