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Reliability-Centered Test Design for EV HVAC, Charging, and Energy Domains

Author(s) Abhishek Devgan
Country India
Abstract The high rate of battery electric vehicles (BEVs) development in the global environment has brought the customer expectations of thermal comfort, reliability in charging, and energy efficiency to the mission-critical level. However, the traditional automotive test procedures, which have been designed to be suitable to internal-combustion-engine (ICE) vehicles, do not offer the systematic risk-prioritization that is needed to test the unique and interdependent electronic, thermal and electrochemical systems of modern EVs. The current Research presents a Reliability-Centered Test Design (RCTD) framework that is customized to three of the highest-risk customer functions aspects of EVs, namely: (1) Heating, Ventilation, and Air Conditioning (HVAC); (2) AC/DC Charging Infrastructure; and (3) Energy Management Systems. Based on Reliability-Centered Maintenance (RCM) approach, Failure Mode and Effects Analysis (FMEA), and risk-priority-number (RPN) ranking, the framework has a systematic way of identifying the highest-consequence failure modes in each domain and mapping them to specific test cases that can be carried out. The RCTD framework has been validated using actual case studies and actual automotive accidents showing an estimated 33% reduction in the mandatory execution of tests and a 90% retrospective defect detectability rate compared to verified EV field failures in global production programs.
Keywords reliability-centered testing, EV HVAC test, battery thermal management, DC fast charging reliability, FMEA, risk priority number, energy management systems, battery management system, ISO 26262, functional safety, EV test design, warranty risk, charge interoperability.
Field Engineering
Published In Volume 4, Issue 11, November 2023
Published On 2023-11-02
DOI https://doi.org/doi.org/10.5281/zenodo.20347982
Short DOI https://doi.org/hb48mt
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