Fault modeling, which is the determination of the effects of a fault on a system, is an effective way for conducting failure analysis and fault diagnosis for complex system. One of the major challenges of fault modeling in complex systems is the ability to model the effects of component-level faults on the system. This paper develops a simulation-based methodology for failure analysis through modeling component-level fault effect on the system level, with application to electric vehicle powertrains. To investigate how a component fault such as short circuit in a power switch or open circuit in a motor winding affects the vehicle system, this paper develops a detailed simulator which allows us to see system and subsystem failure behaviors by incorporating fault models in the system. This fault modeling process provides useful knowledge for designing a reliable and robust fault diagnosis and prognosis procedures for electrified powertrains.

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