Incident: Ford Mustang Mach-E Recall Due to Overheating Battery Contactors.

Published Date: 2022-06-14

Postmortem Analysis
Timeline 1. The software failure incident with the Ford Mustang Mach-E electric vehicles happened from late May 2020 through late May 2022 as per the article [129599]. Therefore, the software failure incident occurred between May 2020 and May 2022.
System 1. High-voltage battery main contactors in Ford Mustang Mach-E electric vehicles [129599]
Responsible Organization 1. Ford Motor Co was responsible for causing the software failure incident with the Mustang Mach-E electric vehicles [129599].
Impacted Organization 1. Customers who own or were planning to purchase the Ford Mustang Mach-E electric vehicles were impacted by the software failure incident [129599].
Software Causes 1. The software cause of the failure incident was a part overheating due to DC fast charging and repeated wide-open pedal events, leading to the high-voltage battery main contactors overheating and potentially welding closed or remaining open, resulting in a loss of propulsion power [129599].
Non-software Causes 1. Overheating of the high-voltage battery main contactors due to DC fast charging and repeated wide-open pedal events [129599].
Impacts 1. Loss of propulsion power in the affected Mustang Mach-E electric vehicles due to overheating of the high-voltage battery main contactors, potentially leading to a crash risk [129599].
Preventions To prevent the software failure incident in the Ford Mustang Mach-E electric vehicles, the following measures could have been taken: 1. Implementing thorough testing procedures during the development phase to identify and address potential software issues before the vehicles are released to the market [129599]. 2. Conducting comprehensive quality assurance checks specifically focused on the high-voltage battery main contactors and their interaction with the software to ensure proper functioning and safety [129599]. 3. Regularly monitoring and analyzing data from the vehicles in the field to detect any anomalies or patterns that could indicate a potential software-related issue, allowing for proactive software updates or recalls if necessary [129599].
Fixes 1. Ford Motor Co is planning to address the software failure incident in the Mustang Mach-E electric vehicles by implementing a software update [Article 129599].
References 1. Ford Motor Co (F.N) [Article 129599]

Software Taxonomy of Faults

Category Option Rationale
Recurring one_organization (a) The software failure incident has happened again at one_organization: Ford Motor Co has experienced software-related issues with its Mustang Mach-E vehicles multiple times. In addition to the recent recall due to a part overheating and causing a loss of propulsion power, Ford had previously issued five recalls for various 2021 Mustang Mach-E vehicles, including one for a software issue that could cause unintended acceleration [129599]. This indicates a recurring pattern of software-related problems within the organization.
Phase (Design/Operation) design, operation (a) The software failure incident in the Ford Mustang Mach-E electric vehicles was related to a design issue. The article mentions that the high-voltage battery main contactors could overheat due to DC fast charging and repeated wide-open pedal events, leading to arcing and deformation of electrical contact surfaces. Ford plans to address this issue with a software update for vehicles built from late May 2020 through late May 2022 [129599].
Boundary (Internal/External) within_system (a) within_system: The software failure incident in the Ford Mustang Mach-E electric vehicles was due to a part overheating, specifically the high-voltage battery main contactors, which could lead to a loss of propulsion power. Ford mentioned that DC fast charging and repeated wide-open pedal events can cause the overheating issue. The company plans to address this issue with a software update expected to begin next month [129599].
Nature (Human/Non-human) non-human_actions (a) The software failure incident in the Ford Mustang Mach-E electric vehicles was primarily due to non-human actions. The issue was related to the high-voltage battery main contactors overheating during DC fast charging and repeated wide-open pedal events, leading to arcing and deformation of electrical contact surfaces. This could result in a contactor remaining open or welding closed, causing a loss of propulsion power while driving [129599]. The solution proposed by Ford to address this issue was a software update to prevent overheating and related failures, indicating that the root cause was not directly linked to human actions.
Dimension (Hardware/Software) hardware, software (a) The software failure incident reported in Article 129599 is related to hardware issues. Ford Motor Co is recalling about 49,000 Mustang Mach-E electric vehicles due to a part that could overheat, specifically the high-voltage battery main contactors. The overheating of these contactors can occur due to DC fast charging and repeated wide-open pedal events, leading to arcing and deformation of the electrical contact surfaces. This hardware issue can result in a loss of propulsion power while driving, increasing the risk of a crash. Ford plans to address this hardware issue with a software update [129599].
Objective (Malicious/Non-malicious) non-malicious (a) The software failure incident described in Article 129599 is non-malicious. The issue with the Mustang Mach-E electric vehicles was related to a part overheating due to DC fast charging and repeated wide-open pedal events, causing the high-voltage battery main contactors to overheat. Ford addressed this issue with a software update to prevent overheating, indicating that the failure was not due to malicious intent but rather a technical flaw in the system [129599].
Intent (Poor/Accidental Decisions) accidental_decisions The software failure incident reported in Article 129599 regarding the Ford Mustang Mach-E electric vehicles was primarily due to accidental_decisions. The issue of overheating and potential loss of propulsion power was caused by the high-voltage battery main contactors overheating due to DC fast charging and repeated wide-open pedal events. Ford addressed this issue with a software update to prevent arcing and deformation of the electrical contact surfaces, which could lead to a loss of propulsion power while driving [129599].
Capability (Incompetence/Accidental) accidental (a) The software failure incident in the Ford Mustang Mach-E electric vehicles was not explicitly attributed to development incompetence. The issue was related to the high-voltage battery main contactors overheating due to DC fast charging and repeated wide-open pedal events, leading to arcing and deformation of electrical contact surfaces. Ford addressed this issue with a software update [129599]. (b) The software failure incident in the Ford Mustang Mach-E electric vehicles was accidental, as it was caused by the high-voltage battery main contactors overheating due to specific usage scenarios like DC fast charging and repeated wide-open pedal events. This accidental overheating could result in a loss of propulsion power while driving, increasing the risk of a crash [129599].
Duration temporary The software failure incident mentioned in Article 129599 is temporary. Ford Motor Co is recalling about 49,000 Mustang Mach-E electric vehicles due to a software issue that can cause the high-voltage battery main contactors to overheat. The company plans to address the issue with a software update expected to begin next month. Until the software update is completed, dealers cannot deliver new vehicles to customers, indicating a temporary nature of the software failure incident [129599].
Behaviour crash (a) The software failure incident described in the article is related to a crash. The article mentions that if an overheated contactor opens while driving, it could result in a loss of propulsion power, increasing the risk of a crash [129599].

IoT System Layer

Layer Option Rationale
Perception None None
Communication None None
Application None None

Other Details

Category Option Rationale
Consequence harm, property, delay, theoretical_consequence The consequence of the software failure incident in the article is related to potential harm to individuals due to the loss of propulsion power caused by the overheating of the high-voltage battery main contactors in Ford Mustang Mach-E electric vehicles. If an overheated contactor opens while driving, it could result in a loss of propulsion power, increasing the risk of a crash [129599].
Domain transportation (a) The failed system in the reported incident was related to the transportation industry. Ford Motor Co announced a recall of about 49,000 Mustang Mach-E electric vehicles due to a software issue that could cause overheating of the high-voltage battery main contactors, potentially leading to a loss of propulsion power while driving [Article 129599]. This incident directly impacts the transportation sector as it involves electric vehicles designed for moving people and goods.

Sources

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