Case studies and practical application of key measurement for electric vehicle circuit inspection: intelligent, data-driven diagnostic systems

The accelerating adoption of battery electric vehicles (BEVs) has heightened the need for reliable maintenance and diagnostic methods for HV electrical systems. While extensive research has focused on battery management and drive control, practical diagnostic frameworks for power-on and charging faults remain limited. This article develops a structured diagnostic methodology that bridges theoretical circuit analysis with field-oriented inspection practice. The architecture and control logic of key subsystems, including the battery pack, HV interlock loop (HVIL), power distribution unit (PDU), and AC charging circuit, are analyzed to elucidate their functional relationships. Based on these models, quantitative diagnostic procedures are proposed for common BEV malfunctions such as power-on failure, AC charging failure, and insulation faults. Tiered resistance and voltage thresholds, signal path validation, and flow-diagram-based fault isolation enable clear and reproducible inspection processes. The proposed framework not only enhances safety and repair efficiency but also establishes a foundation for intelligent, data-driven diagnostic systems in next-generation electric vehicles (EVs).

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