An integrated fault-diagnosis algorithm for a motor sensor of in-wheel independent drive electric vehicles is presented. This paper proposes a method that integrates the high- and low-level fault diagnoses to improve the robustness and performance of the system. For the high-level fault diagnosis of vehicle dynamics, a planar two-track non-linear model is first selected, and the longitudinal and lateral forces are calculated. To ensure redundancy of the system, correlation between the sensor and residual in the vehicle dynamics is analyzed to detect and separate the fault of the drive motor system of each wheel. To diagnose the motor system for low-level faults, the state equation of an interior permanent magnet synchronous motor is developed, and a parity equation is used to diagnose the fault of the electric current and position sensors. The validity of the high-level fault-diagnosis algorithm is verified using Carsim and Matlab/Simulink co-simulation. The low-level fault diagnosis is verified through Matlab/Simulink simulation and experiments. Finally, according to the residuals of the high- and low-level fault diagnoses, fault-detection flags are defined. On the basis of this information, an integrated fault-diagnosis strategy is proposed.
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