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Predictive Maintenance & Telemetry

Target: Traction Inverter & IPMSM Motor · FOC Algorithm Data
Powertrain Health Score
0
Nominal operation
IGBT Est. Life (RUL)
0 hrs
Based on thermal stress model
Model Residual Error
0
Physical vs. Digital Twin Δ
Stator Temperature
0 °C
Within safe operating area

Fault Injection — FTTI Verification

ISO 26262-4 · SG-01 FTTI 100 ms
Click “⚡ Inject Hardware Fault” to run the fault-reaction chain against the FTTI budget.
t=0
Fault injected
8 ms
Plausibility trip
12 ms
Torque ramp-down
45 ms
ASC safe state
100 ms
FTTI limit
Reaction chain: resolver fault → plausibility monitor (TSR-01.1a) → gate driver ASC — awaiting injection —

Live Phase Currents (High-Frequency)

FOC / dq-axis
I_u
I_v
I_w
ANOMALY DETECTED
Digital Twin Residual Log (Kalman Filter)
[0.00s] Twin model initialized. Synchronizing states...
[0.12s] Twin state sync nominal. Residual < 1%.

Prognostics: Remaining Useful Life (RUL)

AI Degradation Model

Predictions derived from real-time thermal cycling and load profiles compared against baseline physics models.

Inverter Phase B (IGBT) 92%
Failure mode: Solder joint fatigue due to ΔT cycles.
Stator Winding Insulation 88%
Degradation: Partial discharge / Thermal aging.
DC-Link Capacitor 96%
Health: ESR drift within 1% of nominal.
Rotor Bearings 74%
Vibration signature indicates minor inner-race wear.

IPMSM Current Vector & Operating Envelope

4 pole-pairs · Ld 0.25 mH / Lq 0.55 mH · ψm 0.075 Wb
Operating point rides the MTPA locus. The voltage-limit ellipse is drawn for the present speed, so it contracts as the machine accelerates and is what forces field weakening. Torque shown here is computed from i_d and i_q, not asserted separately.

Network Zone Classification — Motor Controller ECU

ISO/SAE 21434 · UN R155
ZONE 3
Body & Cabin
TCU · IVI
External Network
CAN GW
ZONE 1 ← HERE
Front Powertrain
Motor MCU
Traction Inverter
OBD
DIAG
Diagnostic I/F
OBD-II Port
Workshop Tool
Bus Interface
CAN FD
500 kbps · ISO 11898
Software Stack
AUTOSAR
SecOC · PDU Router
Cyber Assurance
CAL-2
ISO/SAE 21434 Annex E
Attack Vector
Adjacent
No direct external exposure
Safety Level
ASIL-D
ISO 26262 Part 5 & 6
Gateway Isolation
HW Firewall
Zone 1 → Zone 2 filtered