Incident: Improperly Primed Battery Packs Cause Malfunction in GM EVs

Published Date: 2022-10-24

Postmortem Analysis
Timeline 1. The software failure incident involving the GM Hummer EV and BrightDrop EV600 electric van battery packs occurred between Nov. 9, 2021, and Sept. 28, 2022 [133839].
System 1. Ultium electric-vehicle platform used in the 2022 GMC Hummer EV and BrightDrop EV600 electric van [133839]
Responsible Organization 1. The supplier in charge of the battery packs was responsible for causing the software failure incident by not properly priming or electrocoating certain flanges on the battery packs, leading to the urethane sealant not adhering correctly and allowing water to enter the battery pack, causing a malfunction [133839].
Impacted Organization 1. General Motors [Article 133839]
Software Causes 1. The software cause of the failure incident was related to the battery packs in the 2022 GMC Hummer EV and BrightDrop EV600 electric van. Certain flanges on the battery packs may not have been properly primed or electrocoated, which could prevent the packs' urethane sealant from adhering correctly, allowing water to enter the battery pack and causing a malfunction [133839].
Non-software Causes 1. Improper priming or electrocoating of certain flanges on the battery packs, leading to the urethane sealant not adhering correctly [133839].
Impacts 1. The software failure incident led to a malfunction in the affected vehicles' battery packs, potentially causing the vehicles not to start and triggering malfunction indicators on the gauge cluster [133839].
Preventions 1. Proper quality control measures during the manufacturing process to ensure that all components, including the battery packs, are primed and electrocoated correctly [133839]. 2. Thorough testing and inspection of vehicles, including field testing and internal testing, to identify any potential defects or issues before they lead to malfunctions [133839]. 3. Implementing a robust monitoring system that can detect early signs of malfunction indicators on the gauge cluster to prevent further issues [133839].
Fixes 1. Properly priming or electrocoating the flanges on the battery packs to ensure the urethane sealant adheres correctly [133839].
References 1. National Highway Traffic Safety Administration (NHTSA) - The defect report filed with NHTSA provided information about the issue with the battery packs [133839].

Software Taxonomy of Faults

Category Option Rationale
Recurring one_organization (a) The software failure incident related to the battery packs of certain electric vehicles from General Motors (GM) has happened again within the same organization. GM issued a recall for 735 examples of the 2022 GMC Hummer EV and 89 examples of the BrightDrop EV600 electric van due to issues with the battery packs [133839]. The defect in the battery packs could allow water to enter, causing a malfunction in the vehicles. GM discovered this issue after receiving field reports and an internal report regarding one of its test vehicles. The automaker is still working on developing a permanent remedy for the problem and has not yet finalized the repair procedure [133839]. (b) There is no information in the provided article indicating that a similar software failure incident has happened at other organizations or with their products and services.
Phase (Design/Operation) unknown The article does not mention any software failure incident related to the development phases of design or operation. Therefore, the information regarding the software failure incident in relation to these specific development phases is unknown.
Boundary (Internal/External) within_system (a) within_system: The software failure incident in this case is within the system. The issue with the affected vehicles' battery packs, specifically certain flanges not being properly primed or electrocoated, is an internal defect originating from within the system. This defect could prevent the packs' urethane sealant from adhering correctly, leading to water entering the battery pack and causing a malfunction [133839].
Nature (Human/Non-human) human_actions (a) The software failure incident in this case is not related to non-human actions but rather to a manufacturing defect in the battery packs of the electric vehicles. The issue stemmed from certain flanges on the battery packs not being properly primed or electrocoated, which could lead to the urethane sealant not adhering correctly and allowing water to enter the battery pack, causing a malfunction [Article 133839]. (b) The failure in this case was due to human actions, specifically a manufacturing oversight in the production process of the battery packs for the electric vehicles. The defect report filed with NHTSA highlighted that the flanges on the battery packs may not have been properly primed or electrocoated, indicating a human error in the manufacturing process that led to the software failure incident [Article 133839].
Dimension (Hardware/Software) hardware (a) The software failure incident in the article is related to hardware. The issue with the affected vehicles, the 2022 GMC Hummer EV and BrightDrop EV600 electric van, stems from the battery packs. Specifically, certain flanges on the battery packs may not have been properly primed or electrocoated, which could prevent the packs' urethane sealant from adhering correctly. This hardware issue could allow water to enter the battery pack, causing a malfunction in the vehicles [133839].
Objective (Malicious/Non-malicious) non-malicious (a) The software failure incident in this case is non-malicious. The issue with the affected vehicles, specifically the 2022 GMC Hummer EV and BrightDrop EV600 electric van, stems from a defect in the battery packs where certain flanges were not properly primed or electrocoated, leading to a problem with the urethane sealant adherence. This could allow water to enter the battery pack, causing a malfunction [Article 133839]. The failure was not due to any malicious intent but rather a manufacturing defect that could potentially impact the vehicles' performance.
Intent (Poor/Accidental Decisions) unknown The software failure incident related to the recall of the 2022 GMC Hummer EV and BrightDrop EV600 electric van was not directly attributed to poor decisions or accidental decisions. The issue stemmed from a manufacturing defect in the battery packs of the electric vehicles, specifically related to certain flanges not being properly primed or electrocoated, leading to a failure of the urethane sealant and potential water intrusion into the battery pack [133839]. This incident appears to be more of a quality control or manufacturing issue rather than a result of poor or accidental decisions.
Capability (Incompetence/Accidental) accidental (a) The software failure incident in this case is not related to development incompetence but rather to a manufacturing defect in the battery packs of the affected vehicles. The issue stemmed from certain flanges on the battery packs not being properly primed or electrocoated, which led to the urethane sealant not adhering correctly, potentially allowing water to enter the battery pack and cause a malfunction [Article 133839]. (b) The software failure incident in this case can be categorized as accidental, as it was not a deliberate action but rather a result of a manufacturing oversight in the assembly of the battery packs. The defect was discovered after GM received field reports and an internal report, prompting the automaker to initiate a voluntary safety recall to address the issue [Article 133839].
Duration temporary The software failure incident described in the article is temporary. The article mentions that General Motors discovered the issue with the battery packs after receiving field reports and an internal report regarding test vehicles. GM found the potential defect and decided to initiate a voluntary safety recall. As of the time of publication, GM does not have a proper fix in place and is still working to develop a permanent remedy. The supplier in charge of the battery packs has already fixed the issue on its assembly line, indicating that the failure is temporary until a permanent fix is implemented [Article 133839].
Behaviour other (a) crash: The software failure incident in the article is not described as a crash where the system loses state and does not perform any of its intended functions [133839]. (b) omission: The software failure incident in the article is not described as an omission where the system omits to perform its intended functions at an instance(s) [133839]. (c) timing: The software failure incident in the article is not described as a timing issue where the system performs its intended functions correctly, but too late or too early [133839]. (d) value: The software failure incident in the article is not described as a value issue where the system performs its intended functions incorrectly [133839]. (e) byzantine: The software failure incident in the article is not described as a byzantine failure where the system behaves erroneously with inconsistent responses and interactions [133839]. (f) other: The software failure incident in the article is related to a defect in the battery packs of electric vehicles, specifically the failure of certain flanges on the battery packs to be properly primed or electrocoated, leading to the urethane sealant not adhering correctly. This could allow water to enter the battery pack, causing a malfunction. The behavior of the software failure incident is more related to a hardware issue with the battery packs rather than a specific software-related failure behavior [133839].

IoT System Layer

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

Other Details

Category Option Rationale
Consequence property, non-human, theoretical_consequence (d) property: People's material goods, money, or data was impacted due to the software failure The software failure incident described in the article led to a recall by General Motors for 735 examples of the 2022 GMC Hummer EV and 89 examples of the BrightDrop EV600 electric van. The issue stemmed from the battery packs of these electric vehicles, where certain flanges on the battery packs were not properly primed or electrocoated. This defect could prevent the packs' urethane sealant from adhering correctly, potentially allowing water to enter the battery pack and causing a malfunction. As a result, affected owners may experience a series of malfunction indicators on the gauge cluster, and the vehicle might not start as intended [133839].
Domain transportation (a) The failed system in the reported incident is related to the transportation industry. The software failure incident affected General Motors' vehicles, specifically the 2022 GMC Hummer EV and BrightDrop EV600 electric van, which are part of the transportation sector [Article 133839].

Sources

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