formula student electric

Event Name Formula Bharat 2020 < Update with your information (select from dropdown 'Formula Bharat 2020' or 'FSEV 03')

Car Number Exx < Update with your information

Team Name Zeter Racing < Update with your information

University Inventive Thinkers State University < Update with your information

Contact Emails joyful@joyful.net, fsworld_1@fs.com < Update with your information

This template contains two of examples of how to fill out the FMEA. Furthermore, it contains a number of failure modes which are
both starting points and examples for the failures to be covered in your team's FMEA. NOTE: Not every given failure may apply
to every team's system. The given failures may also be incomplete with respect to your specific system. Add failures to
the list, if appropriate for your system.

Change the two complete examples given, i.e. No.1 and 2, to suit your system. Add missing failure modes with respect to your
car's system. Be as complete as possible, adding any failures that affect the safety of your car, the driver, or other persons. Before
submitting your FMEA please make sure it is complete. This way you will avoid unnecessary delays and queries. Please have a
look at the Guidelines available on the website, before filling out the FMEA form.

Edit the coloured cells to your specific data and reset the cell colour to white
Only add additional failures at the end of the list to keep the numbering scheme of the original template. This makes reviewing the
document much easier and thus faster. Do not delete any failures, if they do not apply to your system. Just write "Does not apply."
or similar with a short reason why.

Do not change the template's format!

Seite 1
FMEA definitions of column headers and Key for Severity, Occurance and Detection ratings

Rating Severity (Sev) Occurrence (Occ) Detection (Det)

1 No injuries may be Failure occurrence Certain detection of
caused, but general is very unlikely the failure
safety is affected by this
failure
2 Light injuries may be Relatively few High chance of
caused by this failure failure occurrence detecting this failure
3 Medium injuries may be Occasional failure Medium chance of
caused by this failure occurrence detecting this failure
4 Heavy injuries may be Frequent failure Low chance of
caused by this failure occurrence detecting this failure
5 Fatal injuries may be Persistent failure Failure cannot be
caused by this failure occurrence detected

Component/Item The system or component that is affected

Function What the system or component does
Failure Mode The method by which the component fails
Failure Cause The root cause of the failure
Failure Effect Local What happens locally to the component as a consequence of the failure
Failure Effect Global What happens to other systems or the rest of the vehicle as a consequence of the failure
Sev The severity rating - see table above
Severity Reasoning Your reasoning for the severity rating that is given
Occ The likelihood of the occurrence - see table above
Occurrence Reasoning Your reasoning for the occurance rating that is given
Failure Detection How will the failure be detected - what are the systems on the car that detect this
Det The rating for failure detection - see table
Detection Reasoning Your reasoning for the failure detection rating
Risk Calculated automatically from Sev, Occ and Det
Failure Handling - Vehicle Once a failure has been detected, what is the immediate reaction of the ECU / BMS and the driver to
Failure Handling - Team How do you determine what has failed and what type of action is taken to remedy this? What precau
ce of the failure

ect this

CU / BMS and the driver to mitigate the risk

remedy this? What precautions do you take whilst doing this?
 FB 2020 FMEA
Team Name: Zeter Racing

Car No.: Exx University: Inventive Thinkers State University Contact: joyful@joyful.net, fsworld_1@fs.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 2 All wire insulations chosen with Insulation resistance 1 IMD detects every isolation 8 Isolation Lost Alarm enabled. Appropriate procedure to be
Wiring to GLVS degradation condition if operator voltage potential change and fractures caused by respect to the environment, monitoring system. failure to the chassis, since the IMD opens the AIRs through the executed once the car back in
touches the negative pole uncontrolled muscle additional thermal oder chassis is connected to control Shutdown Circuit the PIT to restore the isolation.
of the battery and the movement due to the electric mechanical protection attached system ground Fault to be identified and
chassis shock. Ventricular fibrillation where needed, all wires are rectified before enabling the
not likely with DC voltages securely attached and AIRs. Insulating gloves to be
up to 600V, therefore not professionaly built to lower the used
severity 5 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 2 All wire insulations chosen with Insulation resistance 1 IMD detects every isolation 8 Isolation Lost Alarm enabled. Appropriate procedure to be
Wiring to the GLVS degradation condition if operator voltage potential change and fractures caused by respect to the environment, monitoring system. failure to the chassis, since the IMD opens the AIRs through the executed once the car back in
touches the positive pole of uncontrolled muscle additional thermal oder chassis is connected to control Shutdown Circuit the PIT to restore the isolation.
the battery and the chassis movement due to the electric mechanical protection attached system ground Fault to be identified and
shock. Ventricular fibrillation where needed, all wires are rectified before enabling the
not likely with DC voltages securely attached and AIRs. Insulating gloves to be
up to 600V, therefore not professionaly built to lower the used
severity 5 risk of damages by vibrations

3 Tractive System Energy transfer Open/live tractive system

Wiring connections when switching
on the tractive system

4 HVD / Tractive Energy transfer HVD / Tractive System

System Connectors become lose
Connectors while driving and eventually
open up, exposing live
contacts
5 Tractive System Protection of tractive system Overcurrent is higher than
Fusing wiring the maximum switch off
current of the used fuse
6 Accumulator Energy Storage Cell temperature above
data sheet specification for
discharging
7 Accumulator Energy Storage Cell temperature above
data sheet specification for
charging (including
regenerative braking)
8 Accumulator Energy Storage Cell voltage above data
sheet specification
9 Accumulator Energy Storage Cell voltage below data
sheet specification
10 Accumulator Energy Storage Cell current above data
sheet specification for
discharging
11 Accumulator Energy Storage Cell current above data
sheet specification for
charging (including
regenerative braking)
12 Accumulator Energy Storage Cooling system (water, air,
oil) fails
13 Accumulator Energy Storage Accumulator is crushed /
cells are mechanically
damaged
14 Accumulator Energy Storage Maintenance plugs
incorrectly assembled
15 Torque Encoder Signaling the pedal position Sensor 1 and Sensor 2
deliver different position
values
16 Torque Encoder Signaling the pedal position Sensor 1 or Sensor 2 signal
(analog or digital) not
plausible
17 Torque Encoder Signaling the pedal position Sensor 1 or Sensor 2
broken
18 Torque Encoder Signaling the pedal position Signal connection (analog
or digital) to Sensor 1 or
Sensor 2 broken
19 Torque Encoder Signaling the pedal position Pedal stuck at maximum
torque position
20 Torque Encoder Signaling the pedal position Digital communication
between sensors and
receiving ECU is corrupted
(e.g. bits change due to
EMI)
21 Torque Encoder Signaling the pedal position Signal connection (analog
or digital) between
implausibility check ECU
and inverter is broken
22 Accumulator Disconnecting the Single Accumulator
Insulation accumulator Insulation Relay short-
Relay(s) circuit
23 Accumulator Disconnecting the Both Accumulator Insulation
Insulation accumulator Relay short-circuit
Relay(s)

FMEA: Page 1 / 7
 FB 2020 FMEA
Team Name: Zeter Racing

Car No.: Exx University: Inventive Thinkers State University Contact: joyful@joyful.net, fsworld_1@fs.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
24 Accumulator Disconnecting the Single Accumulator
Insulation accumulator Insulation Relay control
Relay(s) connection lost
25 Accumulator Disconnecting the Both Accumulator Insulation
Insulation accumulator Relay control connection
Relay(s) lost
26 Pre-Charge Relay Pre-Charging the Pre-Charge Relay short
intermediate circuit circuit
27 Pre-Charge Relay Pre-Charging the Pre-Charge Relay control
intermediate circuit connection lost
28 Pre-Charge Pre-Charging the Pre-Charge Resistor broken
Resistor intermediate circuit / open circuit
29 Discharge Relay Discharging the intermediate Discharge Relay short
circuit circuit
30 Discharge Relay Discharging the intermediate Discharge Relay control
circuit connection lost
31 Discharge Discharging the intermediate Discharge Resistor broken /
Resistor circuit open circuit
32 Motor Controller / Controlling the motor power Motor Controller output
Inverter stage short-circuit
33 Motor Controller / Controlling the motor power Motor Controller control
Inverter connection lost
34 Motor Controller / Controlling the motor power Motor Controller does not
Inverter react plausible to control
input
35 Motor Controller / Controlling the motor power Cooling system (water, air,
Inverter oil) fails
36 Motor Resolver Measures angular motor Motor position resolver
position failed
37 Insulation Monitoring the insulation of Insulation Monitoring
Monitoring Device the tractive system Device lost connection to
reference ground
38 Insulation Monitoring the insulation of Insulation Monitoring
Monitoring Device the tractive system Device lost connection to
39 Insulation Monitoring the insulation of HV+
Insulation Monitoring
Monitoring Device the tractive system Device lost connection to
40 Insulation Monitoring the insulation of HV-
Insulation Monitoring
Monitoring Device the tractive system Device lost power supply
41 Insulation Monitoring the insulation of Insulation Monitoring
Monitoring Device the tractive system Device has a general fault
42 Insulation Monitoring the insulation of Connection between
Monitoring Device the tractive system Insulation Monitoring
Device and powerstage to
open the shutdown circuit is
broken
43 Insulation Monitoring the insulation of Powerstage
Monitoring Device the tractive system (relay/transistor) to open the
shutdown circuit is broken

44 Insulation Monitoring the insulation of Insulation Monitoring

Monitoring Device the tractive system Device not installed
45 Accumulator Monitoring the accumulator AMS Master has a general
Management condition fault (CPU/Software
System erroneous)
46 Accumulator Monitoring the accumulator AMS Slave has a general
Management condition fault (CPU/Software
System erroneous)
47 Accumulator Monitoring the accumulator Temperature Sensor is
Management condition faulty
48 System
Accumulator Monitoring the accumulator Signal connection to
Management condition temperature sensor is
System broken
49 Accumulator Monitoring the accumulator Voltage sense input is
Management condition broken
50 System
Accumulator Monitoring the accumulator Voltage sense wire is
Management condition broken
51 System
Accumulator Monitoring the accumulator Overcurrent in the voltage
Management condition sense wire
52 System
Accumulator Monitoring the accumulator Signal Connection between
Management condition AMS Master and Slave is
System broken
53 Accumulator Monitoring the accumulator Powerstage
Management condition (relay/transistor) to open the
System shutdown circuit is broken

54 Accumulator Monitoring the accumulator Connection between AMS

Management condition and powerstage to open the
System shutdown circuit is broken
55 Accumulator Monitoring the accumulator AMS lost power supply
Management condition
56 System
Accumulator Monitoring the accumulator Cell balancing powerstage
Management condition has a short circuit
57 System
Accumulator Monitoring the accumulator Digital communication
Management condition between AMS master and
System slave is corrupted (e.g. bits
change due to EMI)

FMEA: Page 2 / 7
 FB 2020 FMEA
Team Name: Zeter Racing

Car No.: Exx University: Inventive Thinkers State University Contact: joyful@joyful.net, fsworld_1@fs.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
58 Accumulator Monitoring the accumulator AMS not installed
Management condition
59 System System
Tractive Displaying the status of the Light emitting device broken
Active Light (Red) tractive system
60 Tractive System Displaying the status of the Circuitry erroneos
Active Light (Red) tractive system
61 Tractive System Displaying the status of the Voltage sense connection to
Active Light (Red) tractive system HV+ or HV- broken
62 Tractive System Displaying the status of the Tractive system active light
Active Light (Red) tractive system lost power supply
63 Tractive System Displaying the status of the Light emitting device broken
Active Light tractive system
64 (Green) System
Tractive Displaying the status of the Circuitry erroneos
Active Light tractive system
65 (Green)
Tractive System Displaying the status of the Voltage sense connection to
Active Light tractive system HV+ or HV- broken
66 (Green) System
Tractive Displaying the status of the Tractive system active light
Active Light tractive system lost power supply
67 (Green)
Accumulator Shows, if more than 60VDC Signal connection to HV+ or
Indicator exist behind the AIRs HV- lost

68 Accumulator Shows, if more than 60VDC Lost power supply

Indicator exist behind the AIRs

69 Accumulator Shows, if more than 60VDC Circuitry erroneos

Indicator exist behind the AIRs

70 Ready-To-Drive- Indicating that the vehicle is Speaker/noise producing

Sound ready-to-drive device broken
71 Ready-To-Drive- Indicating that the vehicle is Circuitry erroneos
Sound ready-to-drive
72 Ready-To-Drive- Indicating that the vehicle is Signal connection to ECU
Sound ready-to-drive indicating ready-to-drive-
mode broken
73 Ready-To-Drive- Indicating that the vehicle is Ready-To-Drive-Sound
Sound ready-to-drive module not installed
74 Ready-To-Drive- Indicating that the vehicle is Ready-To-Drive-Sound
Sound ready-to-drive module lost power supply
75 Brake System Checking for implausibility Brake Pedal Sensor broken
Plausibility Device between brake pedal sensor
and power delivered to the
motor(s)
76 Brake System Checking for implausibility Signal connection (analog
Plausibility Device between brake pedal sensor or digital) to Brake Pedal
and power delivered to the Sensor broken
motor(s)
77 Brake System Checking for implausibility Motor current sensor
Plausibility Device between brake pedal sensor broken
and power delivered to the
motor(s)
78 Brake System Checking for implausibility Signal connection (analog
Plausibility Device between brake pedal sensor or digital) to motor current
and power delivered to the sensor broken
motor(s)
79 Brake System Checking for implausibility Brake system plausibility
Plausibility Device between brake pedal sensor device lost power supply
and power delivered to the
motor(s)
80 Brake System Checking for implausibility Powerstage
Plausibility Device between brake pedal sensor (relay/transistor) to open the
and power delivered to the shutdown circuit is broken
motor(s)
81 Brake System Checking for implausibility Connection to powerstage
Plausibility Device between brake pedal sensor to open the shutdown circuit
and power delivered to the is broken
motor(s)
82 Brake System Checking for implausibility Brake system plausibility
Plausibility Device between brake pedal sensor device not installed
and power delivered to the
motor(s)
83 Brake System Signaling the pedal position Sensor 1 or Sensor 2
Encoder broken
84 Brake System Signaling the pedal position Digital communication
Encoder between sensors and
receiving ECU is corrupted
(e.g. bits change due to
EMI)
85 Brake System Signaling the pedal position Signal connection is broken
86 Brake System Signaling the pedal position Interefence between
Encoder multiple systems utilsing
same sensor

FMEA: Page 3 / 7
 FB 2020 FMEA
Team Name: Zeter Racing

Car No.: Exx University: Inventive Thinkers State University Contact: joyful@joyful.net, fsworld_1@fs.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
87 Brake-Over- Detecting an over-travelling Electrical Connection to
Travel-Switch brake pedal shut-down circuit broken
88 Brake-Over- Detecting an over-travelling Switch broken / does not
Travel-Switch brake pedal switch
89 ShutDown Button Opening the shutdown Electrical Connection to
circuit, when pushed shut-down circuit broken
90 ShutDown Button Opening the shutdown Button broken / does not
circuit, when pushed switch
91 Cockpit-mounted Opening the shutdown Electrical Connection to
ShutDown Button circuit, when pushed shut-down circuit broken
92 Cockpit-mounted Opening the shutdown Button broken / does not
ShutDown Button circuit, when pushed switch
93 Tractive System Switches off the tractive Switch broken / does not
Master Switch system switch
94 Grounded Low- Switches off the GLVS Switch broken / does not
Voltage System switch
95 Master Switch
Inertia Switch Opens the shut down circuit Electrical Connection to
in case of a crash shut-down circuit broken
96 Inertia Switch Opens the shut down circuit Switch broken / does not
in case of a crash switch
97 Inertia Switch Opens the shut down circuit Inertia Switch not installed
in case of a crash
98 Tractive System Carrying the current tractive Connection to HV+ or HV-
Measurement system voltage for easy broken
Points measurements
99 LV-DC/DC Converts TS voltage to DC/DC draws to much
converter GLVS voltage current
100 LV-DC/DC Converts TS voltage to DC/DC drains the HV-
converter GLVS voltage battery
101 LV-DC/DC Converts TS voltage to DC/DC overheats
converter GLVS voltage
102 LV-DC/DC Converts TS voltage to GLVS short circuit
converter GLVS voltage
103 GLV System Supplies the GLV with GLV System voltage
Supply energy critically low
104 Vehicle Dynamics Additional influence on Vehicle Dynamics
Function / ECU requested motor torque Function / ECU has a
105 Vehicle Dynamics Additional influence on general fault
Vehicle Dynamics
Function requested motor torque Function / ECU circuitry is
106 Vehicle Dynamics Additional influence on erroneous
Vehicle Dynamics
Function requested motor torque Function / ECU signal
connection to steering
wheel sensor is broken
107 Vehicle Dynamics Additional influence on Steering wheel sensor is
Function requested motor torque faulty
108 Vehicle Dynamics Additional influence on Vehicle Dynamics
Function requested motor torque Function / ECU signal
connection to acceleration
sensor is broken
109 Vehicle Dynamics Additional influence on Acceleration sensor is faulty
Function requested motor torque
110 Vehicle Dynamics Additional influence on Vehicle Dynamics
Function requested motor torque Function / ECU signal
connection to wheel speed
sensor is broken
111 Vehicle Dynamics Additional influence on Wheel speed sensor is
Function requested motor torque faulty
112 Regenerative Controls regenerative Regenerative Braking
Braking Function / braking Function / ECU has a
ECU general fault
113 Regenerative Controls regenerative Associated sensors fail
Braking Function / braking
114 ECU
Regenerative Controls regenerative Connection to associated
Braking Function / braking sensors fails
115 ECU
Regenerative Controls regenerative Rear wheel regenerative
Braking Function / braking braking is activated at high-
ECU speed by mistake
116 Charger Controls charging the Connector is live when not
accumulator connected
117 Charger Controls charging the Accumulator fault which can
accumulator be detected by the AMS

118 Charger Controls charging the Accumulator fault which can

accumulator be detected by the IMD
119 Charger Controls charging the Charging fault leading to
accumulator excessive current

FMEA: Page 4 / 7