Functional Safety Development of Motor Control Unit for Electric Vehicles

Due to robust framework from Government, many environmental and socio-economic benefits and fun to drive aspect, auto industry is transitioning from fuel powered vehicles to electric vehicles. Functional safety is a key factor in the development of new technologies related to electric vehicles. Motor Control Unit is one of the core powertrain system of the electric vehicle, which safety is becoming more and more critical. Motor Control Unit controls electric motor torque, speed and voltage. Malfunctioning behavior of electrical or electronic subsystems in Motor control unit may lead to accidents causing loss of life for the driver, passengers and for other road users.The aim of the paper is to highlight the functional safety concept development for 380V Motor control unit (MCU) according to the ISO26262 standard, including system architectures, item definition, hazard analysis and risk assessment, safety goal derivation, functional safety concept and technical safety concept. To develop the technical safety concept, the three-level monitoring safety concept is adopted. This paper will also cover the warning and degradation concept applicable to MCU in order to avoid any potential harm or damages by any E/E sub system malfunction.