An Exhaustive Examination of the Motor System’s Reliability in Electric Vehicles

Abstract

Due to their unique zero carbon emission feature, electric vehicles (EVs) have garnered increasing interest in recent years. However, concerns persist regarding their reliability, particularly concerning critical components. Efforts have been made to assess the reliability of drive motors in EVs. Yet, given the integration of drive motors and motor controllers as a single system in EVs, a combined assessment is essential for a more accurate reliability prediction. Additionally, considering the multiple components within both drive motors and motor controllers, their structure, type, and characteristics may influence the overall reliability of the motor system, a factor overlooked in previous research. To bridge this knowledge gap, this study investigates the reliability of the entire motor system in pure electric vans, encompassing both drive motors and motor controllers. The research begins with predicting the theoretical failure rates of subassemblies and components within the drive motor and motor controller. Subsequently, based on these predictions, the reliability of the entire motor system is assessed. The findings highlight vulnerable subassemblies and components within the motor system, shedding light on potential shortcomings in existing reliability research. These new insights are deemed crucial for informing future reliability design and maintenance practices for pure electric vans. This study undertakes an exhaustive investigation into the reliability of the motor system in EVs. As EVs gain prominence for their environmental benefits and increasing market share, concerns regarding the reliability of critical components, such as the drive motor and associated control systems, become paramount. While prior research has addressed component-level reliability, this study takes a holistic approach by assessing the entire motor system. Through theoretical modeling and empirical analysis, the study predicts failure rates of subassemblies and components within the drive motor and control systems, culminating in an evaluation of the overall motor system reliability. By uncovering vulnerabilities and potential areas for improvement, this research offers valuable insights to advance the design, development, and maintenance of reliable electric vehicles.