Safe Handling of High Voltage Battery Systems

Electric and hybrid vehicles are becoming more visible on today's roadways and the automotive companies are working hard to make these vehicles as transparent as possible to enhance consumer acceptance. The battery system forms a key part of any of these vehicles and is probably the least understood. With practically no moving parts the battery systems show no visible or audible warning of any latent dangers. This seminar will introduce participants to the risks encountered in handling high voltage battery systems and their component parts. With the understanding of these risks, the seminar will then address how to raise risk awareness and then methods of dealing with those risks. The outcome of this seminar should be improved avoidance of personal injury, reduced risk of reputation loss and product liability actions and reduced risk of loss of property and time.

Students will have an opportunity to participate in a real world battery handling case study scenario in which they will identify solutions for potential risk situations. 

What Will You Learn

By attending this seminar, you will be able to:
  • Identify the handling risks of the battery system
  • Respect the risks and work with them
  • Develop a safety program to manage the risks

Is This Course For You

This seminar is primarily intended for vehicle and battery engineers, battery system integration engineers, battery testing engineers, safety systems engineers, electrical engineers and thermal management engineers recently assigned to their roles or returning to hybrid or electric vehicle programs. It will also be beneficial to those involved in the specification, design, development, testing and planning of hybrid vehicle programs. Prototype shop staff will find the safety protocol aspects helpful.

Materials Provided

This data is not available at this time

Course Requirements

This data is not available at this time


  • High Voltage Batteries
    • Electrochemical energy
    • Construction aspects and controls
    • DC vs AC
    • Lithium Ion aspects
  • Risks of HV Batteries
    • Team exercise: identifying the risks
    • Risk drivers
    • Hazards classifications
    • Cell vs pack level
  • Risk Management
    • Abuse prevention
    • Best practices, design measures, error proofing
    • Prevention & warnings
    • Claims vs. test data
    • Housekeeping
    • Containment
  • High Voltage Issues in Engineering and Manufacturing Environments
    • Avoidance of internal dangers from handling
    • What can go wrong in different environments
    • MSDS
    • Special tools
    • Handling of 'failed' batteries or cells
    • Dealing with an incident - team exercise