Failure mode details of the electronic part of the battery system

Here, the details of the failure of the electronic part are sorted out. The system level FMEA is mainly to establish conceptual problems and confirm the seriousness of the problem. At this level, you can grasp the different designs and the hardware and software FMEA behind the design.

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The so-called software and hardware strategy fault-tolerant design is based on the high RPA, unacceptable state, set Safety Goal to achieve security goals.

4) Battery unit status is summarized to the whole vehicle

a) normal customer use (driving, charging, parking & maintenance)

4.1 Unable to send normal status

(10 4 7) The battery system cannot communicate with the vehicle <= Vehicle Fault Tolerance Design

(10 4 4) Unable to communicate inside the battery system <= Vehicle Fault Tolerance Design / Battery System Fault Tolerant Design

(10 4 7) Electronic module loss of power <= vehicle fault tolerance design [standard voltage test software test]

(10 4 4) Sensor failure

(10 1 4) Communication crash (data transmission error) <= serial communication strategy

4.2 Intermittent transmission of normal status

(10 4 7) The battery system is intermittently unable to communicate with the vehicle <= Vehicle Fault Tolerance Design

(10 4 4) Battery system intermittent internal communication cannot be <= Vehicle fault tolerance design / battery system fault tolerance design

(10 4 7) Intermittent power loss of electronic module <= Vehicle fault tolerance design [Standard voltage test software test]

(10 4 4) Sensor intermittent failure

(10 1 4) Intermittent communication crash (data transmission error) <= serial communication strategy

4.3 Sending normal status information when fault occurs

(10 1 7) MCU failure <= Vehicle fault tolerance design / battery system fault tolerance design

(10 4 4) Sensor information error <= Vehicle fault tolerance design / battery system fault tolerance design

(10 1 4) Intermittent communication crash (data transmission error) <= serial communication strategy

(10 4 7) The battery system cannot communicate with the vehicle <= Vehicle Fault Tolerance Design

(10 4 7) Electronic module loss of power <= vehicle fault tolerance design [standard voltage test software test]

4.4 Intermittent transmission of fault information

(10 4 7) The battery system is intermittently unable to communicate with the vehicle <= Vehicle Fault Tolerance Design

(10 4 4) Battery system intermittent internal communication cannot be <= Vehicle fault tolerance design / battery system fault tolerance design

(10 4 7) Intermittent power loss of electronic module <= Vehicle fault tolerance design [Standard voltage test software test]

(10 4 4) Sensor intermittent failure

(10 1 4) Intermittent communication crash (data transmission error) <= serial communication strategy

4.5 Sending fault information when normal

(10 1 7) MCU failure <= Vehicle fault tolerance design / battery system fault tolerance design

(10 4 4) Sensor information error <= Vehicle fault tolerance design / battery system fault tolerance design

(10 1 4) Intermittent communication crash (data transmission error) <= serial communication strategy

(10 4 7) The battery system cannot communicate with the vehicle <= Vehicle Fault Tolerance Design

(10 4 4) Battery system intermittent internal communication cannot be <= Vehicle fault tolerance design / battery system fault tolerance design

(10 4 7) Electronic module loss of power <= vehicle fault tolerance design [standard voltage test software test]

4.6 Information is incorrect or not sent

(10 4 4) Unable to communicate <= Vehicle Fault Tolerant Design

(10 1 7) MCU failure <= Vehicle fault tolerance design / battery system fault tolerance design

(10 7 4) Sensor lost <= battery system position / structure

(10 4 4 ) Sensor accuracy problem <= battery system position / structure

5) Control and manage the battery cells in the battery system

a) Maintain SOC within the scope of work

5.1 SOC overcharge

(10 4 7) Sensor failure (harness, short circuit to 12V/GND, open circuit)

(10 1 7) MCU failure

(10 4 7) Algorithm error

(10 1 4) Intermittent communication crash (data transmission error) <= serial communication strategy

5.2 SOC over discharge

(10 4 7) Sensor failure (harness, short circuit to 12V/GND, open circuit)

(10 1 7) MCU failure

(10 4 7) Algorithm error

(10 1 4) Intermittent communication crash (data transmission error) <= serial communication strategy

b) temperature control within the range

5.3 Temperature is above safe range

(10 4 4) Insufficient heat dissipation

(10 4 7) Temperature sensor failure (harness, short circuit to 12V/GND, open circuit)

(10 4 4) Battery internal resistance is too high

(10 1 7) External temperature exposure overheating

(10 1 4) External heating

5.4 The temperature is too low during charging

(10 4 7) External cooling

(10 4 7) Temperature sensor failure (harness, short circuit to 12V/GND, open circuit)

c) battery voltage consistency maintenance

5.5 Voltage does not last (stable)

(7 4 7) Sensor failure (harness, short circuit to 12V/GND, open circuit) Charger failure Monomer acquisition circuit Contact resistance is too high Monomer internal resistance is too high Parallel monomer loss

5.6 Monomer voltage is too high

(10 4 7) Sensor failure (harness, short circuit to 12V/GND, open circuit)

(10 4 7) Charger failure

(10 7 7) The contact resistance of the single-chip acquisition circuit is too high

(10 4 7) The internal resistance of the monomer is too high

(10 4 7) Parallel cell loss

5.7 The cell voltage is too low

(10 1 4) Sensor failure (harness, short circuit to 12V/GND, open circuit)

10 1 7) Intermittent communication crash (data transmission error) <= serial communication strategy

(10 4 7) The main relay cannot be disconnected

(10 1 4) Battery pack short circuit

d) maintain the charge and discharge current within a certain range

5.8 Current is too high

(10 4 7) Charger failure

(10 1 4) Fuse failure

(10 4 4) Battery pack short circuit

5.9 Charging current is too low

summary:

a) A lot of the above is the ability to determine the safety situation from the experiment.

b) Details can go down to each sensor, MCU, power supply, and even serial communication & signal output

c) I have the opportunity, I have to do my own design carefully.

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