Page 30 - Australasian Paint & Panel Jul-Aug 2020

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Tech Talk
PAINT&PANEL JULY / AUGUST 2020
WARNING! HIGH VOLTAGE
CAN CURRENT TRAINING PROGRAMMES GIVE BODYSHOPS THE POWER TO COPE WITH AN ERA OF HIGH VOLTAGE VEHICLES? BY DEAN LANDER, HEAD OF REPAIR SECTOR SERVICES, THATCHAM RESEARCH
I
T WOULD BE EASY TO ASSUME
that only fully electric vehi- cles, such as a Tesla or Nissan Leaf, present an increased risk to your business. In reality, any vehicle that contains High Voltage (HV) systems introduces risk. But what proportion of people who will come into contact with
HVs really understand their threat? From having the ability to return a
damaged HV vehicle to the road fully reinstated to prior performance, to protecting staff from the increased risk of electrocution, there is plenty for bodyshops to consider. The elec- trification of the powertrain, intro- ducing HV systems to the modern motor vehicle, is a seismic shift that must be taken seriously.
Training is one of the inevitable solutions to tackle these new dif- ficulties, and it shouldn’t be re- stricted to the technicians who
will work on HV systems. Without
the correct knowledge, anyone coming into contact with an HV - from first re- sponderstoallstaffinandarounda workshop - faces increased risk.
Let’s take a look at each issue in turn.
1A NEW NOMENCLATURE
The number of HVs on UK roads grew from 10,000 in 2010 to a current to- tal of 200,000 [source: Electric vehicles and infrastructure Parliamentary brief- ing paper 2019].
All carmakers are moving towards a cleaner future: witness the rise in adver- tising of new, greener models (not least VW following its recent difficulties). By 2025, we can expect a typical bodyshop to repair an electric vehicle every day.
We’re lacking a standard means of identi- fication (all of the following are HV): fuel cellandbatteryEVs;series,parallel,plug-in and mild hybrids. Everyone involved in re- covery and repair faces greater risks if this classification issue isn’t addressed and peo- ple are consequently unaware of exactly what type of vehicle they are dealing with.
High voltage is generally referred to as an electric component or circuit, with a working voltage of >60-volts and ≤1500-volts DC or >30-volts and ≤1000-volts AC root mean square. Any vehicle that includes components or cir- cuits that meet this definition should be clearly identifiable as HV; all necessary precautions for safe working practice should be instigated to protect all staff.
2THE SHOCKING TRUTH
The days of lifting a bonnet, reach- ing for a spanner and disconnecting the 12v battery to make the vehicle safe are rapidly disappearing. With traditional training, almost everyone in the repair ecosystem from first responder to body- shop technician could identify and dis- connect a 12v battery to make a vehicle safe to work on. With HVs, however,
disconnecting the 12v system does not make the vehicle safe, so new and
additional training is paramount. For instance, not all electrified vehicles are fully electric, and some don’t even require plug-in charg- ing, so the tell-tale sign of a charg-
ing socket may be missing.
When opening the bonnet of this BMW 330e vehicle, at first view, it isn’t obviously an HV. The signs are there but without training they are easy to miss. There is a typical combustion engine in view, so dan- ger might not be obvious. Take a closer look, though, and HV is more apparent. Most recognisable for trained staff would be the orange cables, but these are tucked away at the back of the en- gine and the small warning label on the
BMW 330e can be easily missed. Whatever type of HV you’re handling, the safety aspect is significantly different. High voltage in automotive is generally re- ferred to as above 60-volts, and currently a HV system can operate up to 650v, with increases set for the future. At Thatcham Research, we believe there isn’t enough awareness of the dangers. Factors such as accident damage, use of heat in repair and which capacitors are storing electrical en-
ergy increase risks to technicians.