Multi-dimensional failure risk load prediction of electric motor based on physical model and data-driven approach

Dynamic prediction of failure risk loads is a critical prerequisite for system damage monitoring and service life evaluation. As the failure mechanism of electric vehicle drive motors under multi-source load excitations is complex, and the risk load poses challenges in rapid acquisition, a physics-based and data-driven method for multi-dimensional failure risk load prediction of motors is proposed. Based on actual operational data collected from users, we analyze the failure risk loads of various components of a motor. A physical simulation model of the motor is established to extract multi-dimensional failure risk load time history, and the effectiveness of the simulation model is verified using data from bench tests. Moreover, using the physical model simulation data as a foundation, a two-stage data-driven model is constructed. In the first stage, the genetic algorithm optimized back propagation neural network (GA-BPNN) model is implemented for multi-dimensional loss prediction of the motor, and serves as the primary input for the second stage model, which integrates prediction accuracy and training efficiency. In the second stage, by comprehensively considering the spatial and temporal correlation features with the input layer reconstructed using correlation matrix weights, an improved convolutional neural network with bidirectional long short-term memory (CNN-BiLSTM) model is employed to predict multi-scale loads. Compared with traditional models, the proposed method exhibits significantly improved prediction accuracy, with R 2 greater than 0.95. Furthermore, the damage error between the predicted load and the expected load is within 10%, which provides technical support for reliability evaluation and life prediction of electric motor.