Author:
Roy Dhanush,Kumar Chin Chun
Abstract
Electric vehicles (EVs) have garnered significant attention in recent years due to their distinctive zero carbon emission capability. While their environmental advantages are widely acknowledged, concerns about the reliability of key components, particularly the drive motors and associated controllers, continue to linger. Previous studies have made strides in evaluating the reliability of individual drive motors in EVs. However, given the integrated nature of drive motors and motor controllers in EVs, a comprehensive assessment that considers both components as a unified system is imperative for more precise reliability forecasting. Furthermore, the multifaceted nature of drive motors and motor controllers, encompassing various components with diverse structures, types, and characteristics, can significantly influence the overall reliability of the motor system. Unfortunately, these nuances have often been overlooked in prior research, creating a knowledge gap that needs to be addressed. To address this gap, our study offers a holistic investigation into the reliability of the entire motor system in pure electric vans, which includes both the drive motors and motor controllers. We initiate our research by employing theoretical models to predict the failure rates of individual subassemblies and components within the drive motor and motor controller. Building upon these predictions, we conduct an in-depth assessment of the overall motor system reliability. Our findings reveal the vulnerabilities associated with specific subassemblies and components within the motor system, offering critical insights that challenge some of the prevailing assumptions in existing reliability research. These insights are instrumental in guiding future advancements in reliability design and maintenance practices tailored for pure electric vans. The adoption of EVs continues to grow, driven by their environmental benefits and expanding market share, it becomes increasingly crucial to address concerns related to the reliability of essential components like drive motors and control systems. While previous research has largely focused on component-level reliability, our study adopts a more comprehensive approach, evaluating the entire motor system. Through a combination of theoretical modeling and empirical analysis, we aim to provide a robust framework for predicting failure rates and enhancing the overall reliability of EV motor systems. By uncovering vulnerabilities and potential areas for improvement, this research offers valuable insights to advance the design, development, and maintenance of reliable electric vehicles.