Study on Optimal Design and PHM Methods for New Electrification Systems

Abstract

This study will describe the development of PHM method for electrified systems in mass-produced vehicles. The results demonstrate that the method is not limited to the research subject but can also be applied to newly developed electrified systems, demonstrating continued applicability even when the target is changed. Next, we will provide an overview of the development of PHM method that can be used universally across electrified systems. In Phase 1, we identified key failure modes that could occur in electrified systems using FMEA, based on data collected from design, analysis, and testing. In Phase 2, we explored appropriate diagnostic methods for each failure mode. For gear failures, we developed rule-based indicators and verified their validity through experiments. For bearing failures, we also developed a rule-based approach to determine the presence of a fault. However, due to limitations in predicting the location of the fault, we re-evaluated the method based on data to confirm its validity. For failure modes, we used CAE analysis models to identify differences between normal and fault signals for eccentricity and demagnetization faults. Similar signal differences were also observed in the test results of the target product. Based on this, we were able to build a robust diagnostic model using only a small amount of experimental data. In Phase 3, we developed a device capable of data collection and edge computing capabilities capable of analyzing and diagnosing signals from actual vehicles, enabling the collection and analysis of the necessary data.