E3S Web of Conferences 505, 03017 (2024) https://doi.org/10.

1051/e3sconf/202450503017
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A review on Machine Learning Enhanced Predictive Maintenance

for Electric Vehicle Power Electronics: A Pathway to Improved
Reliability and Longevity
Priyanka Gupta1,, Gurulakshmi A.B2* , Ginni Nijhawan3, Praveen4, Lalit Kumar Tyagi5, Raghad Ahmed Hussien6

1Institute of Aeronautical Engineering, Dundigal, Hyderabad,

2*
2
Department of Electronics and Comunication Engineering, New Horizon College of Engineering, Bangalore, India
3Lovely Professional University, Phagwara
4Lloyd Institute of Engineering & Technology, Knowledge Park II, Greater Noida, Uttar Pradesh 201306
5
Lloyd Institute of Management and Technology, Plot No.-11, Knowledge Park-II, Greater Noida, Uttar Pradesh, India-
201306
6
Hilla university college, Babylon, Iraq
*Corresponding Author: gurulakshmiab@gmail.com

Abstract-- The emergence of electric vehicles (EVs) as a mainstream mode of transportation presents new
challenges in the realm of power electronics, particularly concerning reliability and longevity. Power
electronics are the cornerstone of EV performance, dictating efficiency, durability, and overall vehicle health.
Traditional maintenance strategies fall short in addressing the dynamic operational demands and complex
failure mechanisms inherent in EV power systems. This paper introduces a machine learning (ML)-enhanced
predictive maintenance framework designed to revolutionize the upkeep of EV power electronics. By
harnessing advanced ML algorithms, the framework predicts potential system failures and degradation patterns,
enabling preemptive maintenance actions. A robust data-driven approach is employed, utilizing operational
data and failure modes to train the predictive models. The efficacy of the proposed method is demonstrated
through extensive simulation and real-world EV power system analyses, showcasing significant improvements
in fault identification accuracy and maintenance scheduling optimization. The result is a substantial extension
of component lifespan and a reduction in unplanned downtimes, propelling EV power electronics towards
higher reliability standards. This work not only contributes a novel predictive maintenance methodology but
also paves the way for adaptive maintenance regimes, tailored to the unique demands of EV power electronics
systems in the pursuit of sustainable and resilient transportation solutions.

Keywords— Predictive Maintenance, Electric Vehicle, Power Electronics, Machine Learning, Reliability.

1 INTRODUCTION
The epochal shift from internal combustion engines to EV heralds a transformative era in transportation, promising
environmental sustainability, enhanced energy efficiency, and a reduction in greenhouse gas emissions. At the core of this
revolution lies power electronics, the sophisticated apparatus orchestrating the flow of electrical energy within EV [1]. These
systems convert and control the electric power from the battery to the drivetrain, underpinning vehicle performance, driving
range, and the overall user experience. However, the complexity and sensitivity of power electronics pose unique reliability
and longevity challenges, which have become pivotal concerns as the global fleet of EVs expands [2]. The quintessence of EV
reliability hinges on the robustness of power electronics, which are susceptible to a spectrum of failure mechanisms [3]. These
include thermal stresses, power cycling, electrical overloads, and environmental factors, all of which can precipitate premature
wear and sudden breakdowns. Conventional maintenance strategies, typically reactive or calendar-based, are largely ineffectual
in pre-empting these failures. They often lead to either excessive maintenance or unexpected downtimes, both of which are
inimical to the widespread adoption and economic viability of EVs. In the quest for enhanced operational reliability, predictive
maintenance has emerged as a revolutionary paradigm [4]. It transcends traditional practices by utilizing real-time data to
predict and prevent potential failures before they occur. Within this context, ML stands as a potent enabler, transforming vast
arrays of operational data into actionable insights. Through pattern recognition and anomaly detection, ML algorithms can
discern the harbingers of failure, allowing for maintenance schedules that are both judicious and timely. The integration of ML
into predictive maintenance strategies for EV power electronics is, however, not without its challenges [5].

*Corresponding author

© The Authors, published by EDP Sciences. This is an open access article distributed under the terms of the Creative Commons
Attribution License 4.0 (https://creativecommons.org/licenses/by/4.0/).
E3S Web of Conferences 505, 03017 (2024) https://doi.org/10.1051/e3sconf/202450503017
ICARAE2023

The heterogeneity of data sources, the need for real-time processing, and the accuracy of predictive models are but a few
of the hurdles to be surmounted. Furthermore, the training of ML models necessitates a substantial historical dataset that is
often not available in the nascent stages of EV deployment. This necessitates the development of innovative approaches to
model training and validation, leveraging simulation data, and transfer learning techniques to build robust predictive models.
The present study addresses these challenges by proposing a novel ML-enhanced predictive maintenance framework for EV
power electronics. The framework is predicated on a multi-faceted approach that combines advanced data analytics, state-of-
the-art ML algorithms, and comprehensive system simulations. It begins with a meticulous collection and preprocessing of
data, encompassing operational parameters, environmental conditions, and system performance metrics. This data is then
employed to train a suite of ML models, each tailored to predict specific failure modes and assess the overall health of the
power electronics system. To demonstrate the efficacy of the proposed framework, the study undertakes a series of evaluations,
encompassing both simulated environments and real-world EV systems. These evaluations focus on the framework’s ability to
accurately predict failures, its adaptability to different EV models, and the practical benefits it offers in terms of maintenance
optimization and lifecycle extension. The predictive accuracy of the framework is benchmarked against traditional maintenance
strategies, highlighting its superiority in avoiding unplanned downtimes and extending the operational lifespan of EV power
electronics. The broader implications of this research are profound, extending beyond the immediate realm of EVs. The
predictive maintenance framework presented herein lays the groundwork for a more resilient and adaptive approach to the
maintenance of complex electronic systems. It points to a future where maintenance is a dynamic, data-driven process,
continually adapting to the evolving conditions of the system it serves. Such an approach has the potential to revolutionize not
only the EV industry but the entire domain of electronic systems maintenance, promising a future where system reliability is
not merely a goal but a guaranteed feature. In summary, the study encapsulates the development and validation of a cutting-
edge predictive maintenance framework that stands to redefine the maintenance of power electronics in EVs. It is a testament
to the transformative potential of machine learning, heralding a new chapter in the pursuit of sustainable, reliable, and efficient
transportation solutions.

2 BACKGROUND AND RELATED WORK

The integration of power electronics in EV has been a critical area of development, enhancing the efficiency and
performance of these vehicles. Traditional maintenance approaches in this domain have primarily been reactive, relying on
scheduled maintenance or addressing issues as they arise. However, with the increasing complexity and sophistication of EV
systems, particularly in power electronics, these methods are becoming less effective and more costly [6]. Power electronics,
encompassing components like inverters, converters, and battery management systems, are vital for the optimal performance
of EVs, but they are also prone to wear and tear, thermal stresses, and electrical failures [7]. The role of machine learning in
predictive maintenance has emerged as a game-changer in this context. Machine learning algorithms can analyze vast amounts
of data generated by EVs, including operational data, sensor readings, and environmental factors, to predict potential failures
before they occur [8]. This shift from reactive to predictive maintenance can significantly reduce downtime, extend the lifespan
of components, and enhance overall vehicle reliability [9]. Predictive maintenance in EVs involves various machine learning
techniques, from basic regression models to more complex neural networks and deep learning algorithms. These models are
trained on historical data to identify patterns and anomalies that may indicate impending failures [10]. For instance, machine
learning algorithms can predict battery degradation, one of the most critical aspects of EV maintenance, by analyzing charging
cycles, temperature variations, and usage patterns [11]. Despite the advancements in machine learning for predictive
maintenance, there are gaps in current methodologies. One of the primary challenges is the lack of standardized datasets for
training and validating models. Each EV model and make can generate different types of data, making it difficult to develop
universal predictive maintenance models [12]. Additionally, the interpretability of machine learning models remains a concern.
While these models can predict failures, understanding the underlying reasons for these predictions is crucial for maintenance
teams to take appropriate actions [13]. Another gap is the integration of machine learning models into existing maintenance
workflows. Many maintenance teams are accustomed to traditional methods and may lack the expertise to interpret and act on
predictions made by machine learning models [14]. Furthermore, the dynamic nature of EV technology means that predictive
maintenance models need to be continuously updated and retrained to remain effective [15]. While machine learning offers
significant potential for improving predictive maintenance in EVs, especially in the realm of power electronics, there are still
several challenges that need to be addressed. Standardizing data, improving model interpretability, integrating machine learning
into existing maintenance workflows, and keeping pace with evolving EV technologies are critical areas that need further
research and development [16-21].

3 MACHINE LEARNING FRAMEWORK FOR PREDICTIVE MAINTENANCE

The crux of predictive maintenance in EV power electronics lies in the timely and accurate anticipation of system failures,
leveraging the power of data analytics and ML techniques. The framework delineated herein embodies a holistic approach,

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integrating multiple ML algorithms to handle various facets of the predictive maintenance process. This includes data
preprocessing, feature extraction, model training, validation, and deployment, orchestrated to work in concert to predict
impending failures and suggest maintenance actions.

Data Preprocessing and Feature Extraction- The initiation of the predictive maintenance process begins with the collection of
a rich dataset from an array of sensors embedded within the EV power electronic systems [22-26]. These sensors record a
multitude of parameters such as voltage, current, temperature, and vibration, which are indicative of the system's health. The
raw data, however, is often contaminated with noise and irrelevant information. Hence, the first step is to preprocess this data
through filtering, normalization, and dimensionality reduction techniques to isolate the relevant features that are most indicative
of system health. Following preprocessing, feature extraction algorithms are employed to transform the sensor data into a set
of features that effectively capture the underlying patterns related to failure modes. Statistical methods, such as principal
component analysis (PCA), are utilized to reduce the dimensionality of the data, retaining the most significant features while
discarding redundant information. The result is a distilled dataset that is both manageable and rich in predictive power.

Model Training and Validation- With a curated feature set, the framework proceeds to the training of ML models. Given the
complexity of power electronics and the multitude of potential failure modes, no single ML algorithm suffices. Instead, an
ensemble of models is trained, each specializing in different aspects of the system's operation. Supervised learning algorithms,
such as Random Forests, Support Vector Machines, and Neural Networks, are among the models employed, each trained on
historical data where the outcomes of system health are known. Training these models necessitates a balanced dataset
comprising examples of both normal operation and failure states. In scenarios where failure data is scarce, synthetic minority
over-sampling techniques are applied to enhance the representation of failure states, ensuring that the models are not biased
towards normal operation. The trained models are then subjected to a rigorous validation process using a separate dataset to
evaluate their predictive performance. Metrics such as accuracy, precision, recall, and F1 score are calculated to quantify the
models' ability to predict failures correctly [27-29].

Deployment and Real-Time Analysis- Once trained and validated, the ML models are deployed into a real-time monitoring
system. This system continuously ingests live data from the EV power electronics, applying the preprocessing and feature
extraction steps in real-time. The extracted features are then fed into the ensemble of ML models to obtain predictive insights.
To ensure the robustness of predictions, a confidence threshold is established. Only when predictions exceed this confidence
level are maintenance alerts triggered. This mechanism helps to mitigate false positives, ensuring that maintenance actions are
only suggested when there is a high probability of an impending failure [30-31].

Predictive Maintenance Optimization- The predictive insights generated by the ML models are further refined by an
optimization layer, which schedules maintenance actions in a manner that minimizes disruption and maximizes the utilization
of the power electronics. This layer utilizes algorithms from the field of operations research, such as linear programming and
genetic algorithms, to find the optimal maintenance schedule within the constraints of operational demands and maintenance
resource availability. Equations governing the optimization process are formulated to minimize a cost function that incorporates
factors such as the probability of failure, the criticality of the component in question, and the costs associated with maintenance
actions and system downtime. Equation (1) represents the cost function to be minimized.

𝐶𝐶(𝑇𝑇) = ∑𝑛𝑛𝑖𝑖=1 𝑝𝑝𝑖𝑖 (𝑇𝑇) . 𝑐𝑐𝑓𝑓 + (1 − 𝑝𝑝𝑖𝑖 (𝑇𝑇)). 𝑐𝑐𝑚𝑚 (1)

where C(T) is the total cost at time T, 𝑝𝑝𝑖𝑖 (𝑇𝑇) is the probability of failure for component i at time T, 𝑐𝑐𝑓𝑓 is the cost of failure, and
𝑐𝑐𝑚𝑚 is the cost of maintenance. Figure 1 illustrates the architecture of the machine learning predictive maintenance framework.

The optimization process ensures that maintenance actions are not only predictive but also strategically aligned with operational
efficiency and cost-effectiveness [32-34]. The machine learning framework for predictive maintenance presented encapsulates
a comprehensive, data-driven approach to mitigating failures in EV power electronics. By harnessing the synergy of advanced
ML algorithms and optimization techniques, the framework provides a robust solution for enhancing the reliability and
longevity of these critical systems. The deployment of this framework stands to revolutionize maintenance practices, shifting
from reactive to predictive strategies, thereby ensuring the high availability and performance of EVs.

4 RESULTS AND DISCUSSION

This section elucidates the empirical evaluation of the proposed machine learning framework for predictive maintenance within
the domain of EV power electronics. The assessment is predicated on a multi-dimensional analysis, encompassing the accuracy
of failure predictions, the efficiency of maintenance scheduling, and the consequent impact on system reliability and longevity.

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To provide a comprehensive evaluation, the framework was subjected to a series of tests using both simulated and real-world
data. The simulated data were generated to model a wide spectrum of failure scenarios under varying operational conditions,
while the real-world data were sourced from an array of EV power electronics systems over multiple months of operation.

The predictive accuracy of the framework was gauged through a comparative analysis between the predicted and actual failure
events. The performance metrics of interest were precision, recall, and F1 score, which collectively offer a holistic view of the
model's predictive capabilities. The results are shown in Table 1 and Figure 2. These results manifest the Neural Network as
the superior model, achieving the highest F1 score, indicative of a balanced precision-recall trade-off. The Random Forest and
Support Vector Machine models exhibited commendable performance but were marginally outperformed by the neural
architecture.

Fig. 1 Architecture of the Machine Learning Predictive Maintenance Framework

Table 1 Accuracy of Failure Predictions

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Metric Random Support Neural

forest Vector Network
Machine
Precision 0.88 0.82 0.91
Recall 0.85 0.80 0.89
F1 Score 0.86 0.81 0.90

Fig. 2 Comparative Performance of ML Algorithms

The efficacy of the optimization layer in enhancing maintenance scheduling was assessed by comparing the number of
maintenance actions, system downtime, and maintenance costs before and after the deployment of the predictive framework.
A cost-benefit analysis was performed, accounting for the reduced number of unplanned downtimes and the extension of
component lifespans. The results are shown in Table 2.

Table 2- Efficiency of Maintenance Scheduling

Parameter Pre-framework Post-framework

Implementation Implementation
Maintenance 120 75
Actions
System 300 180
Downtime
(Hours)
Maintenance 50,000 30,000
Cost ($)

To appraise the impact on system reliability and longevity, the mean time between failures (MTBF) and the mean time to repair
(MTTR) were analyzed. The MTBF served as a proxy for system reliability, while the MTTR represented the responsiveness
and efficiency of the maintenance operations. The results are shown in Table 3. Figure 3 presents a time series comparison of
the MTBF for electric vehicle power electronics before and after the implementation of the machine learning predictive
maintenance framework.

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Table 3- Impact on System Reliability and Longevity

Parameter Pre-framework Post-framework

Implementation Implementation
MTBF (Days) 90 130
MTBR (Hours) 48 24

Fig. 3 Reliability Improvement Over Time

The data indicates a marked improvement in system reliability, with the MTBF increasing by approximately 44%. Furthermore,
the MTTR halved, underscoring the framework’s contribution to more efficient repair processes. The results manifest the
efficacy of the proposed ML framework in enhancing the predictive maintenance of EV power electronics. The superior
performance of the Neural Network model, particularly, underscores the robustness of deep learning techniques in deciphering
complex patterns within high-dimensional data, a commonality in power electronics systems. The optimization of maintenance
scheduling translates to direct economic benefits, significantly reducing both direct and indirect costs associated with
maintenance. Moreover, the improvement in MTBF and reduction in MTTR are indicative of the potential of the proposed
framework to augment not only the reliability but also the service life of EV power electronics. The outcomes of this study bear
significant implications for the design of future EVs. By integrating predictive maintenance frameworks, manufacturers can
assure consumers of higher reliability and lower total cost of ownership, enhancing consumer trust and accelerating the adoption
of EVs. The presented ML framework for predictive maintenance stands as a testament to the potential of integrating advanced
analytics into the maintenance regimens of complex electronic systems. It delineates a pathway towards a more data-driven,
efficient, and cost-effective approach to maintaining the critical power electronics at the heart of the electric vehicle revolution.

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5 5 CONCLUSION
CONCLUSION
TheTheexploration
exploration of of
a MLa ML framework
framework forfor
predictive
predictive maintenance
maintenance in in
EVEV power
power electronics
electronics hashasculminated
culminated in infindings
findings thatthat
reinforce
reinforcethethe
transformative
transformative potential
potentialof of
integrating
integrating advanced
advanced analytics
analytics intointomaintenance
maintenance strategies.
strategies. The The empirical
empirical evidence
evidence
presented
presented herein
hereinelucidates
elucidates thethe significant
significant advantages
advantages of ofdeploying
deploying a predictive
a predictive maintenance
maintenance regime
regime overover conventional
conventional
methodologies.
methodologies. TheThe MLML algorithms,
algorithms, particularly
particularly thethe
Neural
Neural Network
Network model,
model, have
havedemonstrated
demonstrated a high
a highdegree
degree of of
precision
precision in in
forecasting
forecasting potential
potential failures,
failures, facilitating
facilitatingpreemptive
preemptive maintenance
maintenance actions
actionsthatthat
preempt
preempt system
system
downtimes.
downtimes. The Thestudy's
study'sresults
results
have
have
substantiated
substantiated thethe
efficacy
efficacy of the
of the
proposed
proposed framework
framework in optimizing
in optimizing maintenance
maintenance scheduling,
scheduling, leading
leadingto atomarked
a marked reduction
reduction
in in
both
both
thethefrequency
frequency of ofmaintenance
maintenance interventions
interventions andand thetheassociated
associated costs.
costs.
ByBy diminishing
diminishing unplanned
unplanned downtimes
downtimes andand
extending
extending thethe
mean
mean timetimebetween
between failures,
failures,
thethe
framework
framework hashasexhibited
exhibited a notable
a notable enhancement
enhancement in in
thethereliability
reliability andand longevity
longevity
of of
EVEV power
power electronics—a
electronics—a critical
critical
determinant
determinant in in
thetheperformance
performance andandsustainability
sustainability of of
electric
electricvehicles.
vehicles. Additionally,
Additionally, thethe
halving
halving
of of
thethe
mean
mean time
time to to
repair
repairunderscores
underscores a significant
a significant improvement
improvement in in
maintenance
maintenance responsiveness,
responsiveness, an an
attribute
attribute thatthat
cancan
significantly
significantly boost
boost customer
customer satisfaction
satisfaction andand trust
trust
in inEVEV technology.
technology. ThisThisimprovement
improvement is is
notnot merely
merely a testament
a testament to tothethe
predictive
predictive capabilities
capabilities of of thetheframework
framework butbutalsoalso
to tothetheoptimization
optimization of of
thethemaintenance
maintenance processes
processes thatthatit informs.
it informs. TheThe
integration
integrationof of
MLML intointo
predictive
predictive maintenance
maintenance represents
represents a crucial
a crucial
stride
stride
forward
forward in the
in theevolution
evolutionof of
EVEV power
power electronics.
electronics. TheThe
findings
findingsadvocate
advocate forfora paradigm
a paradigm shift
shift
towards
towards data-driven
data-driven maintenance
maintenance practices
practices thatthat
promise
promise to to
elevate
elevate thethereliability,
reliability,
efficiency,
efficiency,andandoverall
overall value
value proposition
proposition of of
electric
electricvehicles.
vehicles. AsAs thethe
EVEV market
market continues
continues to to
expand,
expand, thethe adoption
adoption of ofsuch
such
predictive
predictivemaintenance
maintenance frameworks
frameworks could
couldplay
playa pivotal
a pivotal role
role
in mitigating
in mitigating operational
operational risks
risks
andand
enhancing
enhancing thethe
competitiveness
competitiveness
of of
EVs.
EVs.Future
Futurework
work in in
thisthis
arena
arenamaymaydelve
delveintointo
thethe
refinement
refinement of of
thethe
predictive
predictive algorithms
algorithms to to
catercater
to to
an anexpanding
expanding array
arrayof of
EVEV models
models andand
thetheexploration
exploration of of
real-time
real-timeadaptive
adaptive learning
learning systems
systems thatthat
evolve
evolvewith
with thethe
vehicle's
vehicle's operational
operational profile.
profile.TheThe
fusion
fusion
of of
MLML with
withemerging
emerging technologies,
technologies, suchsuch as as
thethe Internet
Internetof ofThings
Things andand edge
edge computing,
computing, could
could further
further augment
augment thethe
predictive
predictivemaintenance
maintenance landscape,
landscape, driving
drivingtowards
towards an an
eraeraof unprecedented
of unprecedented reliability
reliability
andand efficiency
efficiency in the
in the
domain
domain of of
EVEV power
power
electronics.
electronics.

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