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This study investigates the root cause of motor over-temperature torque limitation observed during endurance testing of a new energy vehicle, identified as an electronic water pump stall fault. Analysis reveals intermittent voltage drops in the pump's power supply, abruptly decreasing from the rated 12 V to 2.5–3.7 V before recovery. Within this voltage range, the pump's drive module malfunctions due to power instability, triggering stall protection. However, upon voltage recovery, the drive chip fails to auto-reset, compounded by the absence of a software reset command, resulting in restart failure and recurrent stall detection. After three consecutive stalls, the system outputs a 1.5 s low-level pulse followed by a 1 s high-level pulse, reporting a persistent stall fault. By optimizing the pump's control logic—including transient voltage response handling and auto-reset functionality—the issue was resolved. The solution not only enhances pump robustness but also provides a diagnostic framework for similar faults across vehicle models.

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Fault Diagnosis and Improvement Measures for Electronic Water Pumps in New Energy Vehicles

  • 会议论文

  • 发表日期：

    2026年

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  • Yaqing Zhang,
  • Shengchao Li,
  • Xiaoqiang Cheng,
  • Chunhui Gong,
  • Zhenyu Zhang

摘要

This study investigates the root cause of motor over-temperature torque limitation observed during endurance testing of a new energy vehicle, identified as an electronic water pump stall fault. Analysis reveals intermittent voltage drops in the pump's power supply, abruptly decreasing from the rated 12 V to 2.5–3.7 V before recovery. Within this voltage range, the pump's drive module malfunctions due to power instability, triggering stall protection. However, upon voltage recovery, the drive chip fails to auto-reset, compounded by the absence of a software reset command, resulting in restart failure and recurrent stall detection. After three consecutive stalls, the system outputs a 1.5 s low-level pulse followed by a 1 s high-level pulse, reporting a persistent stall fault. By optimizing the pump's control logic—including transient voltage response handling and auto-reset functionality—the issue was resolved. The solution not only enhances pump robustness but also provides a diagnostic framework for similar faults across vehicle models.