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Automotive Electric Vehicle High-Voltage Crash Safety

30 Chapters
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01
Course overview
scope, concepts, and technical context of high-voltage crash safety in electric vehicles.
technicalhigh-voltage
02
High-voltage system architecture in EVs
battery pack, busbars, inverters, and motor connections relevant to crash scenarios.
High-voltagearchitecture
03
Crash safety regulatory landscape
FMVSS 305, ECE R94/R95, GB 38031, and UN GTR 20 requirements for high-voltage integrity.
regulatorylandscape
04
Electrical hazards in crash events
shock, arc flash, thermal runaway, and electrolyte exposure mechanisms.
Electricalelectrolyte
05
High-voltage isolation and insulation monitoring
principles, thresholds, and post-crash detection strategies.
High-voltageisolation
06
Crash sensing and detection
accelerometers, pressure sensors, and algorithms for timely HV disconnection.
detectionaccelerometers
07
Pyrotechnic and electromechanical disconnects
fuse, contactor, and pyro-fuse operation in crash events.
Pyrotechnicelectromechanical
08
Battery pack mechanical design for crash
enclosure, cell arrangement, and energy absorption structures.
mechanicalenclosure
09
Structural crashworthiness of battery enclosures
materials, geometry, and intrusion resistance.
Structuralcrashworthiness
10
High-voltage cable routing and protection
shielding, grommets, and cut-off strategies in deformation zones.
High-voltageprotection
11
Post-crash electrical isolation verification
measurement methods, safety procedures, and pass/fail criteria.
Post-crashelectrical
12
Thermal runaway propagation mitigation
cell spacing, barriers, and venting design for crash-induced damage.
propagationmitigation
13
Crash testing for HV safety
sled tests, full-scale barrier impacts, and component-level validation.
full-scalecomponent-level
14
Simulation and CAE for HV crash safety
FEA, multiphysics, and abuse modeling workflows.
SimulationCAE
15
Battery management system (BMS) crash response
state monitoring, fault handling, and limp-home strategies.
managementBMS
16
High-voltage interlock loop (HVIL) design and diagnostics for crash integrity.
High-voltage interlock loop (HVIL) design and diagnostics for crash integrity.
High-voltageinterlock
17
Emergency response and first responder safety
cut loops, labeling, and extrication procedures.
Emergencyresponse
18
Post-crash battery fire suppression and containment
suppression agents, cooling, and off-gassing management.
Post-crashsuppression
19
Recycling and disposal of crash-damaged HV batteries
safe handling, transport, and regulatory compliance.
Recyclingdisposal
20
Case study
side pole impact and battery intrusion in a typical BEV platform.
intrusionBEV
21
Case study
rear-end collision and high-voltage bus short-circuit risk.
rear-endcollision
22
Case study
undercarriage impact and coolant ingress into battery pack.
undercarriage
23
Design for crash safety
integration of HV components with crumple zones and load paths.
integrationcomponents
24
Testing and certification of HV crash safety
test setups, instrumentation, and data analysis.
certificationinstrumentation
25
Failure analysis and forensic engineering of HV crash incidents
root cause and corrective actions.
analysisforensic
26
Advanced materials and structures for HV crash protection
composites, foams, and hybrid designs.
Advancedmaterials
27
Cybersecurity and functional safety (ISO 26262) considerations for crash-related HV controls.
Cybersecurity and functional safety (ISO 26262) considerations for crash-related HV controls.
Cybersecurityfunctional
28
Global harmonization and future trends in EV high-voltage crash safety standards.
Global harmonization and future trends in EV high-voltage crash safety standards.
harmonizationhigh-voltage
29
Practical engineering task
design a HV disconnection strategy for a given crash pulse.
disconnectionstrategy
30
Practical engineering task
evaluate post-crash HV safety compliance for a battery electric vehicle.
evaluatepost-crash