Battery failure has traditionally been a major concern
for electric
vehicle (EV) safety, and early fault diagnosis will reduce many EV
safety accidents. However, the short-circuit signal is generally very
weak, so it is still a challenge to achieve a timely warning of battery
failure. In this paper, an initial microfault diagnosis method is
proposed for the data of electric vehicles in actual operation. First,
a robust locally weighted regression data smoothing method is proposed
that can effectively remove noisy data and retain fault characteristics.
Second, an ordinary-least-squares-based voltage potential feature
extraction method is proposed, which can effectively capture the small
fault features of battery cells and achieve early warning. Third,
a reference cell selection method based on K-means clustering is proposed,
which can effectively reduce the false alarms caused by the inconsistency
of each cell. Fourth, the Fréchet algorithm is introduced into
the field of battery pack fault diagnosis and combined with thresholds
for battery pack fault diagnosis and localization to accomplish the
diagnosis and early warning of minor faults. Finally, the fault diagnosis
method is validated by three actual running electric vehicles to verify
the effectiveness, reliability, and robustness of the method.