Overview
This half-day training provides an introduction to electrical safety for professionals involved in developing automotive high-voltage (HV) components and systems for electric vehicles (EVs), plug-in hybrid electric vehicles (PHEVs), hybrid electric vehicles (HEVs), and fuel-cell electric vehicles (FCEVs).
The course examines electrical hazards and the layered protection measures used to support safe HV system design and operation. Participants receive an overview of automotive requirements and standards including FMVSS 305, CMVSS 305, UN Regulation No. 100, ISO 6469, and SAE J1766, as well as their relationship with the ISO 26262 functional safety framework. Related topics include the effects of current on the human body, ingress-protection ratings, protection against electric shock, charging, and EV batteries.
Through practical examples, the training introduces physical, sneak-circuit, electrical and electronic, and process-based protection measures used in automotive HV development.
Intended Audience
This course is intended for professionals involved in developing, integrating, evaluating, or overseeing automotive HV components and systems. It is particularly relevant for:
- Electrical, electronic, hardware, and systems engineers working on automotive HV systems
- Engineers developing components or systems for EVs, PHEVs, HEVs, or FCEVs
- Functional safety engineers evaluating the relationship between HV safety and ISO 26262
- Verification, validation, and test engineers responsible for automotive HV safety measures
- Engineering managers and technical leads overseeing HV product-development programs
- Product-compliance and regulatory professionals working with automotive HV requirements
- Automotive OEM and supplier personnel responsible for HV components or systems
Note: This course focuses on automotive HV product development. It does not cover workplace electrical-safety requirements or practices under OSHA requirements, NFPA 70E, or CSA Z462.
Objectives
By the end of this course, participants will be able to:
- Explain the primary electrical hazards associated with automotive HV systems
- Recognize key automotive HV safety standards and regulatory requirements
- Understand the relationship between automotive HV safety and ISO 26262
- Describe how physical, sneak-circuit, electrical and electronic, and process-based protection layers support HV safety
- Recognize considerations related to electric shock, current effects, and ingress protection
- Identify relevant safety considerations for EV, PHEV, HEV, and FCEV components and systems
Agenda
Below you will find an outline of the training course schedule.
- Introduction to High-Voltage Electrical Safety
- Overview of HV Systems
- Importance of Electrical Safety
- Protective Provisions
- Automotive HV Safety Standards
- FMVSS 305 / CMVSS 305
- UNECE R100
- ISO 6469
- SAE J1766
- ISO 26262
- Layers of Protection
- Physical Protection
- Sneak-Circuit Protection
- Electrical/Electronic (E/E) Protection
- Process Protection

