New approach for performing failure analysis of fuel cell-powered vehicles

Safety of hybrid-electric and fuel cell vehicles is a critical aspect of these new technologies, since any accident exposing occupants of such vehicles to unconventional hazards may result in significant setbacks to successful market penetration. Fuel cell and hybrid-electric drive systems are complex, and it is essential to perform a thorough analysis to determine critical failure conditions. There are several safety concerns for routine operation of such systems, particularly for hydrogen-fueled vehicles. A modified Failure Modes and Effect Analysis (FMEA) has been developed, along with a Criticality Analysis (CrA), to identify potentially hazardous conditions for crash and non-crash situations. A mathematical model of fuel cell operation has been developed and used here in conjunction with the FMEA. Component failures during the event modes are simulated using vehicle models developed with Matlab Simulink tools. Six simulation models were created using the software. In addition, a preliminary finite element model of a fuel cell vehicle, using a Ford Taurus (91′) model year sedan, has been developed and implemented. This finite element model is used as a demonstration of the crash simulation of the vehicle.