Summary of Fatal Faults in Drive Motor System of New Energy Vehicles

1

Fault name: stator winding

Failure Mode: Burnout

Fault description: The motor windings are burned out due to short circuit or high operating temperature of the motor, and the motor needs to be replaced

2

Fault name: stator winding

Failure Mode: Breakdown

Fault description: The insulation breakdown of the motor winding causes a short circuit in the motor casing or a short circuit between turns of the winding, and the motor needs to be replaced

3

Fault name: motor speed/position sensor

Failure Mode: Functional Failure

Fault Description: The motor speed/position signal cannot be generated, causing the drive motor system to fail to work

4

Fault name: rotor spline

Failure Mode: Fractured or Chipped

Fault description: The rotor spline is broken or polished, and the torque cannot be transmitted

5

Fault name: Wiring board

Failure Mode: Burnout

Fault Description: The electrical connection between the controller and the motor fails and needs to be replaced

6

Fault name: Wiring board

Failure Mode: Breakdown

Fault description: short circuit between the output lines of the controller or short circuit to the shell

7

Fault name: motor bearing

Failure Mode: Fragmentation

Fault description: The motor bearing is broken and cannot support the rotor normally, the motor needs to be replaced

8

Fault name: motor bearing

Failure Mode: Burnout

Fault Description: Motor bearing temperature is too high

9

Fault Name: Controller Capacitance

Failure Mode: Burnout

Fault description: The capacitor itself or the connection of the controller is invalid and needs to be replaced

10

Fault Name: Controller Capacitance

Failure Mode: Breakdown

Fault Description: Short circuit between the positive and negative poles of the controller capacitor or to the shell, need to be replaced

11

Fault name: controller power device

Failure Mode: Burnout

Fault description: The power device function fails and needs to be replaced

12

Fault name: controller power device

Failure Mode: Breakdown

Fault description: short circuit between the anode, cathode and gate of the power device or the terminal to the shell, need to be replaced

13

Fault Name: Controller Voltage/Current Sensor

Failure Mode: Burnout

Fault description: The sensor function fails, causing the controller to fail to operate normally and needs to be replaced

14

Fault Name: Controller Voltage/Current Sensor

Failure Mode: Breakdown

Fault Description: The sensor is short-circuited between the positive and negative poles or to the shell, causing the controller to fail to operate normally and needs to be replaced

15

Fault name: charging contactor/main contactor

Failure Mode: Burnout

Fault description: The wire package or contact of the contactor is burned, resulting in functional failure and needs to be replaced

16

Fault name: charging contactor/main contactor

Failure Mode: Clearance Out of Tolerance

Fault description: The contactor cannot be reliably contacted or disconnected, causing the controller to fail to operate normally and needs to be replaced

17

Fault Name: Circuit Board

Failure Mode: Burnout

Fault Description: Some components of the circuit board are burned out, resulting in the loss of some or all functions of the circuit board, and the controller cannot operate

18

Fault Name: Circuit Board

Failure Mode: Breakdown

Fault description: Some components of the circuit board break down or the live part breaks down on the mounting support and the shell, resulting in the loss of some or all functions of the control board, and the controller cannot operate normally

19

Fault name: Charging resistor

Failure Mode: Burnout

Fault Description: The controller cannot operate normally and needs to be replaced

20

Fault Name: Fuse

Failure Mode: Burnout

Fault Description: The controller cannot operate normally and needs to be replaced

twenty one

Fault name: cables and connectors

Failure Mode: Burnout

Fault description: The cables and connectors are short-circuited or grounded due to wear or other reasons, causing the controller to fail to work normally

twenty two

Fault name: temperature sensor

Failure Mode: Burnout

Fault description: The sensor function fails, the controller cannot work normally, and needs to be replaced

twenty three

Fault name: temperature sensor

Failure Mode: Breakdown

Fault description: short circuit between signal lines or short circuit to the shell, the controller cannot work normally and needs to be replaced

twenty four

Fault name: motor mounting bracket

Failure mode: fall off

Fault description: The motor has obvious displacement, and the car cannot move

25

Fault name: motor permanent magnet

Failure Mode: Performance Decay

Fault description: The performance of the motor is lower than the index specified in the technical conditions, resulting in a decline in the power performance of the vehicle

26

Fault Name: Communication

Failure Mode: Functional Failure

Fault Description: The controller does not work normally and needs to be replaced

27

Fault Name: Software

Failure Mode: Functional Failure

Fault Description: The controller does not work normally and needs to be replaced


Post time: Apr-22-2023