Safe Handling of High Voltage Battery Systems C1019

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.

Learning Objectives

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

Who Should Attend

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.


SAE course, Introduction to Hybrid and Electric Vehicle Battery Systems (ID#C0626), is recommended as a prerequisite. Material presented will be practical in nature and is based on selected fundamentals of chemistry, materials science, electrical and mechanical engineering. An undergraduate degree in electrical, mechanical or chemical engineering will assist in gaining maximum benefit from the material presented. Experience or training in battery electrochemistry is helpful, but not essential.

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

  • 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

Registration for the web seminar (live, online) is available on a per-person basis, similar to purchasing a seat in a classroom. The fee includes one connection to WebEx training center, using a PC with internet access and VoIP or a telephone,* and access to a secure course in the SAE Learning Center for presentations, supplemental materials, assignments, and learning assessment. To enjoy a more personalized experience, use of a webcam is encouraged.

*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 VoIP. 

Although WebEx will automatically launch when you join the web seminar, you are encouraged to test your setup in advance of the course start date. Click here, then follow the onscreen instructions.

Erik J. Spek or Kevin Konecky

Mr. Spek is Chief Engineer for TÜV SÜD Canada, a member of the global TÜV SÜD third party testing services organization for cell and battery manufacturers, vehicle OEMs and utility grid users of energy storage systems. He is also a consultant in the field of energy storage systems focusing on applications, verification testing, cell and battery production facilities safety and sodium ion battery development. Mr. Spek is co-holder of a patent for next generation sodium metal chloride architecture for low cost and very high energy density. He has authored articles on Weibull statistics for battery life and BEV range modeling and has been active in the battery industry since 1984. Mr. Spek is a member of SAE International and is a Certified Manufacturing Engineer with SME. He received an M.A.Sc. from the University of Waterloo and is a registered Professional Engineer in Ontario, Canada.

Mr. Kevin Konecky recently joined Byton Automotive as Director of Powertrain; responsible for all development and design activities for the high-voltage powertrain. Byton is a newer global company developing an innovative and connected long-range electric vehicle. Recently, as an Energy Storage Systems consultant for Total Battery Consulting, where he’s worked with a number of companies in the field of Energy Storage Systems (ESS) for automotive, stationary and consumer applications. Mr. Konecky has been a career-long proponent of strong product development and validation plans that ensures a robust product for production. Mr. Konecky has worked in the advanced vehicle and battery industry for 20 years at Fisker Automotive, General Motors, EnerDel, Cobasys and Lockheed Martin. Mr. Konecky has a BS in Electrical Engineering from Clarkson University (Potsdam, NY) and a MS in Electrical Engineering from Purdue (IUPUI-Indianapolis, IN).


Duration: 1 Day
CEUs: .7

Fees: $599.00

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