99.999% of people, even after they have what DC electricity is, explained to them, will only know of or encounter two sorts.
1.5 VDC primary cells like AA, C, D etc.
12 VDC secondary lead acid batteries in their car.
So, DC is “safe”, hark back to edison and tesla/westinghouse etc.
In my trade as a marine engineer 30 years ago working on stuff that was old then, I would *often* come across huge banks of traction cells (big slabs of battery shaped like a slim pack of business cards) each one being 2 VDC, made up into big parallel and series connected banks that often ran to about 110 VDC.
It was instantly fatal to fuck with it, metal spectacles, metal watch straps, metal rings, and of course spanners and other tools, would result in horrific injuries and sometimes death, and then there was the voltage and current itself, with DC you get two seemingly random choices, depending on *which* muscle groups spasm and lock up when the power hits them, you either get thrown clear and suffer torn muscles and ligaments, or you get clamped on and the torn muscles and ligaments and all the rest of you start to cook, literally.
In later years in IT I’d see similarly huge DC battery banks in telephone switch exchanges, but the voltage was much lower, usually 48 VDC, still enough to very badly injure you, and possibly kill you… so not *as* dangerous as 110 VDC, but not “safe” by any means.
Bus bars would be slabs of solid copper bar, 2″ x 1″ and up, and it was common to space the +ve and -ve bus bars by enough distance that you couldn’t put one hand on one and one hand on the other by accident, so +ve down on side of a battery bank and the -ve down the other side 10 feet away or more.
Live superheated steam and heavy rotating machinery were other things that were treated with similar levels of respect, fuck with it and die, make a mistake and die, lose focus or attention and die, and if you don’t die and do live, you injuries might be so severe and painful you wish you did.
Now, in 2017, we are getting EV’s on the road with three times these DC voltages, and similar current delivery capacities, and if 110 VDC is possibly fatal, 350 VDC is fucking lethal.
It’s all very well to say “it’s contained” and that “safety precautions” have been made, but the people making these choices and decisions and designing this shit didn’t grow up working with 110 VDC and the injuries and fatalities it created… I did, I personally knew first hand;
- one guy, we’ll call him Fred, his metal frame spectacles fell off, shorted the terminals on a big 110 VDC bank being charged by a 2 cylinder Gardner diesel and DC genny, tops of the batteries blew off taking all his face and both eyeballs and both ears and much of his neck and throat, he lived, with some hearing in one ear.
- another guy, we’ll call him Tom, stainless steel rolex watch strap completed the circuit between a cable he was handling and an improperly shorted battery cage frame, his hand came off, though the stump was mainly cauterised.
- two other guys, call them Dick and Harry, both had a hand clamp on and the power went through their bodies, killing and cooking them at the same time.
Three of these four incidents happened within 100 feet of me, people who weren’t there attempt to be grisly as say they assume it is the smell that stays with you.. it isn’t, it’s the taste, that shit gets in the air and you breathe it in and taste it.
All batteries are basically chemical storage mediums, it’s chemistry at work inside the battery, and you can pull an isolator all you want, that chemistry is still there, wanting to work… just gimme a fucking circuit bitch, any circuit will do.
So yeah, I’m sure Tesla et al can design an EV that doesn’t cook the unwary when then a rear light cluster is changed out, but what of firefighters and recovery guys and anyone else involved with an accident damaged vehicle?
As someone who worked recovery for a while, I can tell you one of the first things you did with a mangled wreck was check the engine compartment, if you saw diesel injectors, you relaxed, if you saw spark plugs, you started to get cautious, if you saw LPG plumbing, you started to get very very cautious.
As someone who worked in motorway recovery, and who was also a time served marine engineer, I can tell you now, if I was still in recovery, my policy would be I’m not touching your fucking wrecked EV, not with anything less than a grab claw on the end of a HIAB anyway.
I had occasion to look inside the guts of an EV late last week, it only just occurred to me today, those big beefy DC power cables weren’t armoured, not properly… in the boats the SWA cable was itself run in thick wall steel pipe duct. and it was already tucked away behind an outer steel hull and some inner steel bulkheads… in a telephone exchange the busbars were contained within a very robust reinforced concrete building with some brick exterior cladding…
In an EV it’s all behind biscuit tin gauge metal and monocoque pressed construction.
If there is one thing I know in life it is that “projected” and “real” are never the same thing, those euro ncap crash tests and videos can look as impressive as fuck, then in real life you get to a job and it don’t make no odds if the car was no stars or five stars for crash protection, 40+ tons of lorry and cargo just went through it like it was tissue paper.
The only way you can make 100 series connected 3.4 VDC cells safe is by making 25 separate banks of 4 in series with physical breakers in between, so that all the breakers open simultaneously with the airbag, and in a way that they can’t be closed or shorted .
Won’t be happening before the fatalities start to mount.
Don’t take my word for it, go talk to someone with hands on experience of working with high voltage and current DC systems… they’ll all say the same thing, for any voltage or current combination, DC is more scary than AC, and when you add in secondary cell high voltage DC, it’s really not something to trifle with or under-estimate.
Great article, nasty stories. I’ll never moan about an A.C. tingle again.
Re: safety concerns, I’m sure that ‘Lessons Will Be Learned’ and ‘Nobody Could Have Known’
Batteries, the newest old tech around. Maybe in another 100 years the E.V. industry will understand the most fundamental component of it’s products.
BTW, any idea what the electrical spec of the old fashioned milk floats was? Not a joke question, they trundled around for years and I never heard any disaster stories (Top speed of 2mph combined with a 5 ton pig iron chassis probably helped any accident damage electrocutions…)
Comment by justwanttocommentblog — September 4, 2017 @ 4:47 pm
Lots of them were 72 VDC, used traction cells, speed control was a series of big bulky contacts that brought more and more windings in curcuit.
Lots of electric fork lifts were 48/72 VDC too and used traction cells too.
If ever I was going off grid I’d be using traction cells, 700 ampere hour per 2 volt DC cell, I’d run 24 VDC and inverters, 2 series strings in parallel for 1400 Ah, or three for 2100 Ah, or four for 2800, which if you like your watts…
700 amperes 48 volts = 33,600 watt hours per string, so 4 strings is 120 kWh stashed away, and the bastards will deep cycle and last and last and last, and you can always replace just the one bad cell….
fuck tesla power walls.
Comment by wimminz — September 4, 2017 @ 7:22 pm
yeah, that’s kind of like how they finally figured out they maybe oughta put weight sensors in the seats of normal cars.
i was contracting on the Virginia side of DC when the incident happened that changed that law. you see, the NHTSA had mandated that all new cars be equipped with airbags and that all the airbags be automagically deployed in a crash.
so, whether you were personally leery about having a shaped high explosive charge positioned less than 2′ ( less oftentimes ) from your face and aimed right at you made no never mind. unca-daddy .gov knew what was good for you, you silly goose.
so, there was a woman, minding her own business, driving around the loop road around the Fair Oaks mall. and every so often, there were speed bumps. so she drives over the speed bump, as you do.
well, something was wrong with the bumper impact sensor and the airbags got deployed. yes, from simply driving over a speed bump at moderate speed. fortunately for the driver, the airbags deployed and kept her from receiving any injury whatsoever from the speed bump “impact”.
the problem, and you knew there was going to be one, was that her daughter had been sitting in the front passenger seat.
you see where this is going? i used the past tense for a reason.
can you imagine what you would do if you drove over a speed bump, your airbags went off for no reason, and once you had collected yourself and you looked over in the passenger seat you found that your child had been decapitated?
that’s why we got disable switches for the passenger bags and weight sensors in all front seats now. the .gov never cared about all those little old ladies sitting 6″ from the steering wheel due to their short legs, but you have a child murdered by idiotic .gov policy practically in the capitol city? .gov weasels sat up and took notice.
Comment by bob k. mando — September 6, 2017 @ 7:29 am