High-voltage safety systems
Interlocks, isolation monitoring, pyro fuses and crash shutdown.
You'll learn
- Explain high-voltage safety systems at engineering level
- Read the numbers that define the behaviour
- Apply the idea to a real pack
Overview
Layered protection means several independent systems must all fail before a person can be hurt. Learn the layers before you go near a pack.
In depth
- High-voltage interlock loop through every HV connector
- Continuous isolation resistance monitoring
- Pyrotechnic fuse fired by the crash sensor
- Automatic contactor opening on airbag deployment
- Active discharge of the DC link within seconds
- Orange cabling and warning labels on every HV component
Only qualified technicians
Pack voltages are lethal, arc energy is high, and capacitors stay charged after shutdown. Never work on high-voltage systems without training and correct PPE.
Find the component
Find the safety device
Locate the pyro fuse, the interlock loop and the service disconnect.
Find: Pyro fuse
Key takeaways
Remember this
- Protection is layered and independent.
- Crash signals open contactors and can fire a pyro fuse.
- Never assume a pack is dead — verify.
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