Fault classification method for the driving safety of electrified vehicles

A fault classification method is proposed which has been applied to an electric vehicle. Potential faults in the different subsystems that can affect the vehicle directional stability were collected in a failure mode and effect analysis. Similar driveline faults were grouped together if they resembled each other with respect to their influence on the vehicle dynamic behaviour. The faults were physically modelled in a simulation environment before they were induced in a detailed vehicle model under normal driving conditions. A special focus was placed on faults in the driveline of electric vehicles employing in-wheel motors of the permanent magnet type. Several failures caused by mechanical and other faults were analysed as well. The fault classification method consists of a controllability ranking developed according to the functional safety standard ISO 26262. The controllability of a fault was determined with three parameters covering the influence of the longitudinal, lateral and yaw motion of the vehicle. The simulation results were analysed and the faults were classified according to their controllability using the proposed method. It was shown that the controllability decreased specifically with increasing lateral acceleration and increasing speed. The results for the electric driveline faults show that this trend cannot be generalised for all the faults, as the controllability deteriorated for some faults during manoeuvres with low lateral acceleration and low speed. The proposed method is generic and can be applied to various other types of road vehicles and faults.