Fuel Cell Vehicles

This information report provides an overview of a typical high voltage electric propulsion vehicle (xEV) and the associated on-board safety systems typically employed by OEM’s to protect these high voltage systems. The report aims to improve public confidence in xEV safety systems and dispel public misconceptions about the likelihood of being shocked by the high voltage system, even when the vehicle has been damaged. The report will document select high voltage systems used for xEV’s and describe safety systems employed to prevent exposure to the high voltage systems.

This SAE Information Report identifies and defines the preferred technical guidelines relating to safety for vehicles that contain High Voltage (HV), such as Electric Vehicles (EV), Hybrid Electric Vehicles (HEV), Plug-In Hybrid Electric Vehicle (PHEV), Fuel Cell Vehicles (FCV) and Plug-In Fuel Cell Vehicles (PFCV) during normal operation and charging, as applicable. Guidelines in this document do not necessarily address maintenance, repair, or assembly safety issues.

Electric, Fuel Cell and Hybrid vehicles may contain many types of high voltage systems. Adequate barriers between occupants and the high voltage systems are necessary to provide protection from potentially harmful electric current and materials within the high voltage system that can cause injury to occupants of the vehicle during and after a crash. This SAE Recommended Practice is applicable to Electric, Fuel Cell and Hybrid vehicle designs that are comprised of at least one vehicle propulsion voltage bus with a nominal operating voltage greater than 60 and less than 1,500 VDC, or greater than 30 and less than 1,000 VAC. This Recommended Practice addresses post-crash electrical safety, retention of electrical propulsion components and electrolyte spillage.

This SAE Information Report contains definitions for HEV and EV terminology. It is intended that this document be a resource for those writing other HEV and EV documents, specifications, standards, or recommended practices.