formula student electric

FORMULA SAE ELECTRIC - 2013 FMEA

Car No.: 607 University: IAUCTB Contact: Seyed Fakhreddin Marvastizadeh, Fakhreddin.Marvasti@gmail.com
FMEA No.: Component/Item Function Failure Mode Failure Cause Failure Effect Sev Severity Reasoning Occ Occurrence Reasoning Failure Detection Det Detection Reasoning Risk Failure Handling - Vehicle Failure Handling - Team Comments
Local Global

1 Tractive System Energy transfer Positive pole lost isolation Wiring insulation Potentially dangerous Possible chassis reference 4 Burns by electric arc, bruises and 2 All wire insulations chosen with Insulation resistance 1 IMD detects every isolation failure 8 Isolation Lost Alarm enabled. IMD Appropriate procedure to be executed
to GLVS degradation condition if operator voltage potential change fractures caused by uncontrolled respect to the environment, monitoring system. to the chassis, since the chassis is opens the AIRs through the Shutdown once the car back in the PIT to restore
Wiring touches the negative pole muscle movement due to the electric additional thermal oder connected to control system Circuit the isolation. Fault to be identified
of the battery and the shock. Ventricular fibrillation not likely mechanical protection attached ground and rectified before enabling the
chassis with DC voltages up to 600V, therefore where needed, all wires are AIRs. Insulating gloves to be used
not severity 5 securely attached and
professionaly built to lower the
risk of damages by vibrations
2 Tractive System Energy transfer Negative pole lost isolation Wiring insulation Potentially dangerous Possible chassis reference 4 Burns by electric arc, bruises and 2 All wire insulations chosen with Insulation resistance 1 IMD detects every isolation failure 8 Isolation Lost LED light enabled. IMD Appropriate procedure to be executed
to the GLVS degradation condition if operator voltage potential change fractures caused by uncontrolled respect to the environment, monitoring system. to the chassis, since the chassis is opens the AIRs through the Shutdown once the car back in the PIT to restore
Wiring touches the positive pole of muscle movement due to the electric additional thermal oder connected to control system Circuit the isolation. Fault to be identified
the battery and the chassis shock. Ventricular fibrillation not likely mechanical protection attached ground and rectified before enabling the
with DC voltages up to 600V, therefore where needed, all wires are AIRs. Insulating gloves to be used
not severity 5 securely attached and
professionaly built to lower the
risk of damages by vibrations
3 HVD / Tractive Energy transfer from/to Connectors are overheated Connectors are not Temperature raise Fire, Explosion 4 Burns 2 All wire insulations chosen with Insulation resistance 1 IMD detects every isolation failure 8 Isolation Lost LED light enabled. IMD Appropriate procedure to be executed
converter selected properly respect to the environment, monitoring system. to the chassis, since the chassis is opens the AIRs through the Shutdown once the car back in the PIT to restore
System Connectors additional thermal oder connected to control system Circuit the isolation. Fault to be identified
mechanical protection attached ground and rectified before enabling the
where needed, all wires are AIRs. Insulating gloves to be used
securely attached and
professionaly built to lower the
risk of damages by vibrations
4 HVD / Tractive Energy transfer HVD / Tractive System Connectors are weak or Tractive system power Vehicle stops 1 No injuries 2 All wires are securely attached Insulation resistance 1 IMD detects every isolation failure 2 Isolation Lost LED light enabled. IMD Appropriate procedure to be executed
Connectors become lose not connected properly disconnected and professionaly built to lower monitoring system. to the chassis, since the chassis is opens the AIRs through the Shutdown once the car back in the PIT to restore
System Connectors while driving and eventually the risk of damages by vibrations connected to control system Circuit the isolation. Fault to be identified
open up, exposing live ground and rectified before enabling the
contacts AIRs. Insulating gloves to be used

5 Tractive System Protection of tractive system Overcurrent is higher than Short circuit happen or Tractive system power Vehicle stops 1 No injuries 2 Components such az motor Insulation resistance 1 IMD detects every isolation failure 2 Isolation Lost LED light enabled. IMD Replacing fuse
wiring the maximum switch off component failure disconnected, fuse blown controller are build professionally monitoring system. to the chassis, since the chassis is opens the AIRs through the Shutdown
Fusing current of the used fuse connected to control system Circuit
ground
6 Accumulator Energy Storage Cell temperature above data Unsuitable battery box Cell life time is reduced Fire, Explosion 5 Fire might cause burns and death 1 Control the cell BMS the battery AIR's 1 BMS measure temperature of 5 Isolation Lost LED light enabled. BMS Open relays
sheet specification for design considerably temperature and cooling system cells individually and detect opens the AIRs through the Shutdown
discharging overheating Circuit
7 Accumulator Energy Storage Cell voltage below data Battery indicator failure Cell life time is reduced It won't be possible to recharge 1 No injuries 2 The indicator is professionally Battery voltage indicator 1 Indicator measure accumulator 2 PCM control discharging Open relays
sheet specification considerably anymore built voltage
8 Accumulator Energy Storage Cell current above data Short circuit, Precharge Cell life time is reduced Cell will overheat 2 It can cause fire or explosion 1 Our battery is suitable for our Fuse, PCM 1 PCM measure current, fuse 2 PCM or fuse open the circuit Open relays
sheet specification for failure considerably motor protect from high current
discharging
9 Accumulator Energy Storage Cell current above data BMS failure, charger Cell life time is reduced Cell will overheat 2 It can cause fire or explosion 1 The charger is professionally built BMS 1 BMS control over current and 2 BMS cut off the charging process Disconnect the charger
sheet specification for failure considerably over voltage during charging
charging
10 Accumulator Energy Storage Cooling system (water, air, Cooling system supply Cell's temperature raise Fire, Explosion 5 Fire and explosion might cause 1 All wires are securely attached By human 4 The cooling system is on the 20 Stop the vehicle check the cooling system wiring,
oil) fails disconnected burns and death and professionaly built to lower controllers behind the driver Reattach the connectors if necessary.
the risk of damages by vibrations
11 Accumulator Energy Storage Accumulator is crushed / Crash, collision Cell's death, temperature Fire, Explosion 5 Fire and explosion might cause 1 Cells are protected from side BMS 5 Temperature rises quickly and 25 Get a fire extinguisher take the battery pack away from the
cells are mechanically raise burns and death impact by accumulator container it is slowly dissipated to cell's vehicle to a safe place
damaged tap, the thermistor can't detect
it properly

12 Torque Encoder Signaling the pedal position Pedal stuck at maximum Throttle springs failure Torque encoder send The driver can't stop the car 4 Accident can be happen that may 1 The throttle is professionally built By human 1 Driver can directly detect the 4 Press the cockpit shutdown button Open relays
torque position maximum signal to causes injuries or death. problem to open the AIR's
controller
13 Accumulator Disconnecting the Single Accumulator The AIR failure, external AIR temperature raise Spark, fire 4 Fire might cause burns 1 The AIR is professionally built IMD detects short circuit 1 IMD detects short circuit and 4 Isolation Lost LED light enabled. IMD Open relays
accumulator Insulation Relay short-circuit conductive object cause and open the AIR's opens the AIRs through the Shutdown
Insulation Relay(s) short circuit between the it has acceptable safety Circuit
AIR input and output
14 Accumulator Disconnecting the Single Accumulator Connectors are weak or Can not control the AIR's Tractive system power cut off 1 No injuries 1 All wires are securely attached By driver 1 Throttle is not work properly when 1 Reconnect the separated connectors Check the contactors control wiring
accumulator Insulation Relay control not connected properly anymore and professionaly built to lower actuated by driver and replace the necessary parts.
Insulation Relay(s) connection lost the risk of damages by vibrations
15 Pre-Charge Resistor Pre-Charging the Pre-Charge Resistor broken Weak resistor connection, Inrush current will apears in Battery or motor controller may 3 Battery damaging may cause fire,burn 1 The discharge circuit resistor is there is a ground isulation 3 It is hard to figure out this failure 9 Repalace the resistor If contactor is damaged it should be
intermediate circuit / open circuit bad selection of resistor the precharge circuit get damaged because of and spark selected properly and safety test before the competition for replaced with new one
power and resistance, inrush parameter is considered the driver
overheat current

16 Discharge Resistor Discharging the intermediate Discharge Resistor broken / Weak resistor connection, cause discharge circuitry The internal controller 3 After vehicle shutdown the controller 1 The discharge circuit resistor is use an indicator to check 4 It is hard to figure out this failure 12 Replace the discharge resistor with a
circuit open circuit bad selection of resistor failure capacitor internal capacitors still has energy in selected properly and safety the capacitor's energy for new one
power and resistance, wont discharge after vehicle itself and it is dangerous if throttle is parameter is considered the driver
overheat shutdown actuated by someone
17 Tractive System Displaying the status of the Tractive system active light Connector failures, Wiring Dangerous condition if Car is energised and no one 5 Electrocution 1 Operator removes the interlocks One can compare the TSAL 1 One can compare the TSAL state 5 Repair TSAL
tractive system lost power supply insulation degradation operator touches the HV knows and HVD before working on the state to the voltmeter on the to the voltmeter on the battery
Active Light bus car battery pack(indicator) pack(indicator)
18 Ready-To-Drive- Indicating that the vehicle is Speaker/noise producing Buzzer blown, connector Dangerous condition if Car is energised and no one 5 Electrocution 1 Operator removes the interlocks One can see state of the 2 One can see state of the voltmeter 10 Repair or replace buzzer
ready-to-drive device broken or lose disconnected operator touches the HV knows and HVD before working on the voltmeter on the battery on the battery pack(indicator)
Sound supply bus car pack(indicator)

19 Insulation Monitoring the insulation of Insulation Monitoring Device bad connection Loss of high voltage power Vehicle stops 4 Possible electric shock, burns, Death, 2 Bender will properly connected IMD LED light will turn on 1 According to the FSAE Rules 8 Reconnect IMD and lost connection
the tractive system lost connection to reference Injuries
Monitoring Device ground
20 Insulation Monitoring the insulation of Insulation Monitoring Device bad connection Main relays won't be No HV will be available 1 No injuries 4 Connections are always fragile By human 1 Power cut off 4 Reconnect IMD
the tractive system lost power supply closed
Monitoring Device
21 Motor Controller / Controlling the motor power Cooling system (water, air, bad connection Temperature raise Batteries, motor controller and 4 Electrocution, damaging major 1 Every components have their own By human 1 Temperature overheat warning 4 Reconnect lost connection
oil) fails other component get damaged components, fire, spark, explosion cooling method, especially air LED light
Inverter from over heating cooling use in the vehicle
22 Insulation Monitoring the insulation of Insulation Monitoring Device Calibration, voltage spike IMD doesn't detect a Possible electrical shock if 4 May cause death, injuries 1 Bender will properly connected There is a ground isulation 3 It is not detected so often 12 Replace IMD
the tractive system has a general fault ground fault there is an available current and terminated test before the competition
Monitoring Device loop
23 Brake-Over- Detecting an over-travelling Electrical Connection to Wiring insulation The system doesn’t shut it may cause crash, death and 4 crash 1 Brake pedal is properly designed By driver 3 It is not detected in time 12 Driver can open the shutdowm button
brake pedal shut-down circuit broken degradation/bad down in the case of crash explosion May cause death, injuries manually if the problem would be
Travel-Switch connection detected in time.
24 Tractive System Displaying the status of the Circuitry erroneos Some mistake in pcb Dangerous condition if no one knows when the car is 5 electrocution 1 The pcb and the circuit is One can compare the TSAL 1 the driver will notice this quickly 5 check the connections of the circuit
tractive system design or connections operator touches the HV energised designed carefully and the state to the voltmeter on the
Active Light bus connections would be checked battery pack(indicator)

FMEA: Page 11