Incident: Chevrolet Volt Battery Fire Incident Investigation.

Published Date: 2011-12-01

Postmortem Analysis
Timeline 1. The software failure incident involving the Chevrolet Volt's battery pack catching fire happened three weeks after a crash test [54830]. 2. The incident was first reported in June [54830]. 3. The article [54830] was published on 2011-12-07. 4. Estimation: The software failure incident likely occurred in June 2011.
System 1. Chevrolet Volt's battery pack [54830, 9080] 2. Lithium-ion battery coolant system [54830, 9080]
Responsible Organization 1. The software failure incident in the Chevrolet Volt, where the battery caught fire after a crash test, was caused by an electrical short resulting from crystallized coolant, which is part of the battery's cooling system [54830, 9080].
Impacted Organization 1. General Motors (GM) [54830, 9080] 2. Chevrolet Volt owners [54830, 9080] 3. National Highway Traffic Safety Administration (NHTSA) [54830, 9080]
Software Causes 1. unknown
Non-software Causes 1. Coolant leaks in the Volt's battery pack leading to an electrical short and subsequent fire [54830, 9080] 2. Failure to drain the battery of power post-crash as per safety protocol [54830, 9080] 3. Design issues with the Volt's battery pack, leading to potential revisions and retrofits [9080]
Impacts 1. The software failure incident involving the Chevrolet Volt's battery pack catching fire after a crash test had significant impacts on General Motors (GM) and Volt owners. GM had to strengthen the battery pack to prevent coolant leaks and potential fires [54830]. 2. The incident led to a federal investigation by the National Highway Traffic Safety Administration (NHTSA) into the safety of the Volt's battery pack, causing concerns among the 6,400 Volt owners [9080]. 3. GM considered redesigning the Volt's battery pack and even offered to buy back Volts from concerned owners, in addition to providing free loaner vehicles [9080]. 4. The incident raised questions about post-crash protocols for electric and plug-in hybrid vehicles, emphasizing the importance of proper procedures for handling batteries after a crash [9080]. 5. Despite the incident, GM emphasized the safety of the Volt and its positive reception by consumers, but acknowledged the need for ensuring post-crash protocols to address any potential safety issues [9080].
Preventions 1. Implementing a post-crash safety protocol that requires draining the battery of power after a crash test could have prevented the software failure incident [54830, 9080]. 2. Strengthening the battery pack design, including reinforcing the case and circuitry, to better protect the coolant system in a side-impact crash could have prevented the software failure incident [54830]. 3. Conducting thorough investigations and analysis of all aspects of the battery, including circuit boards, chemical reactions, and coolant systems, to identify potential issues and prevent future battery fires could have prevented the software failure incident [54830, 9080].
Fixes 1. Strengthening the Volt's battery pack to prevent coolant leaks in accidents [54830] 2. Laminating the battery's circuitry and reinforcing its case to better protect the coolant system in a side-impact crash [54830]
References 1. General Motors (GM) - The articles gather information from GM regarding the software failure incident related to the Chevrolet Volt's battery pack [54830, 9080]. 2. National Highway Traffic Safety Administration (NHTSA) - The articles mention NHTSA's involvement in investigating the fires related to the Volt's battery pack [54830, 9080]. 3. Associated Press - The articles reference information provided by the Associated Press regarding the investigation and details of the incidents [54830, 9080]. 4. Reuters - The articles mention information provided by Reuters regarding GM's findings and proposed solutions to prevent future battery fires [54830, 9080]. 5. Wall Street Journal - The articles mention information reported by the Wall Street Journal regarding GM's consideration of buying back Volts from concerned owners [9080]. 6. OnStar system - The articles mention that GM is alerted to crashes by the OnStar system in every Volt, which dispatches an engineer to drain the energy from the car's pack [9080]. 7. J.D. Power & Associates - The articles mention J.D. Power & Associates' statement about the Volt being well-received by consumers and being a safe car [9080]. 8. Detroit Free Press - The articles mention the Detroit Free Press reporting on the number of Volt owners who have requested a loaner vehicle [9080].

Software Taxonomy of Faults

Category Option Rationale
Recurring one_organization (a) The software failure incident related to the Chevrolet Volt's battery catching fire after a crash test has happened again at General Motors. The incident occurred three weeks after a side-impact crash test, leading to a fire in the vehicle's battery [54830]. General Motors is taking steps to strengthen the battery pack and prevent coolant leaks to avoid such incidents in the future [54830]. (b) The software failure incident related to battery fires after crash tests has not been reported to have occurred at other organizations or with their products and services in the provided articles.
Phase (Design/Operation) operation (a) The articles do not mention any software failure incident related to the design phase of the system development. (b) The software failure incident mentioned in the articles is related to the operation phase. The incident involved fires in the Chevrolet Volt's battery several weeks after crash tests, which were attributed to an electrical short caused by crystallized coolant, leading to the battery catching fire [54830, 9080]. The failure was linked to the operation or misuse of the system, specifically the post-crash safety protocol not being followed, which required draining the battery of power after a crash test [54830].
Boundary (Internal/External) within_system, outside_system (a) within_system: The software failure incident related to the Chevrolet Volt's battery catching fire was primarily due to factors originating from within the system. The incident was caused by an electrical short resulting from crystallized coolant, which led to the battery catching fire [54830]. The failure analysis focused on examining various aspects of the battery, including circuit boards, the chemical reaction storing and discharging energy, and the coolant system itself to determine the root cause of the fires [54830]. Engineers proposed solutions such as laminating the battery's circuitry and reinforcing its case to better protect the coolant system in case of a side-impact crash [54830]. (b) outside_system: The software failure incident was also influenced by factors originating from outside the system. The National Highway Transportation Safety Administration (NHTSA) was not informed of the post-crash safety protocol for the Volt, which requires draining the battery of power after a crash [54830]. This lack of communication and adherence to safety protocols contributed to the incident. Additionally, the article mentions that the fire investigators cleared the Volt and its electric charger of starting a house fire in North Carolina, indicating that the charger was a victim of the fire, not the cause [54830].
Nature (Human/Non-human) non-human_actions, human_actions (a) The software failure incident in the articles is primarily related to non-human actions. The incident was caused by a coolant leak in the Volt's lithium-ion battery, which led to an electrical short and subsequent fires in dormant vehicles [54830, 9080]. The failure was not directly attributed to human actions but rather to a design flaw in the battery pack's coolant system. (b) Human actions were involved in the response to the software failure incident. General Motors' CEO announced potential redesigns of the battery pack and the consideration of buying back Volts from concerned owners [9080]. These actions were taken in response to the federal investigation and to reassure consumers, indicating human intervention in addressing the software failure incident.
Dimension (Hardware/Software) hardware (a) The software failure incident occurring due to hardware: - The software failure incident involving the Chevrolet Volt's battery catching fire was attributed to a coolant leak in the battery pack, which is a hardware-related issue [54830, 9080]. (b) The software failure incident occurring due to software: - There is no mention of the software failure incident being directly caused by software-related factors in the provided articles.
Objective (Malicious/Non-malicious) non-malicious (a) The articles do not mention any malicious intent or actions related to the software failure incident. [54830, 9080] (b) The software failure incident was non-malicious and was related to a design flaw in the Chevrolet Volt's battery pack, specifically concerning the coolant system and the potential for fires after a crash test. The failure was attributed to the crystallized coolant causing an electrical short, leading to the battery catching fire. General Motors was working on strengthening the battery pack to prevent coolant leaks and potential future fires. The incident was a result of unintended design issues rather than any malicious actions. [54830, 9080]
Intent (Poor/Accidental Decisions) accidental_decisions The software failure incident related to the Chevrolet Volt battery fires was primarily due to contributing factors introduced by accidental decisions rather than poor decisions. The incident was caused by an electrical short resulting from crystallized coolant, which was an unintended consequence of the design and composition of the battery system [54830, 9080]. The decision to use liquid coolant in the battery system was not a poor decision in itself, as it is a common practice in electric vehicles, but the crystallization of the coolant leading to the electrical short was an accidental outcome that was not foreseen during the design phase.
Capability (Incompetence/Accidental) accidental (a) The software failure incident occurring due to development incompetence: - The software failure incident related to the Chevrolet Volt's battery catching fire was not directly attributed to development incompetence but rather to a coolant leak causing an electrical short [54830]. - General Motors and investigators were examining all aspects of the battery, including circuit boards and the chemical reaction for storing and discharging energy, to determine the cause of the fires in dormant vehicles. The investigation focused on preventing coolant leaks to avoid future battery fires [54830]. (b) The software failure incident occurring accidentally: - The incident of the Chevrolet Volt's battery catching fire was described as an accidental event resulting from crystallized coolant causing an electrical short, leading to the battery fire [54830]. - The fires in the Chevrolet Volt's battery were reported to have occurred several weeks after crash tests, indicating an accidental nature of the incident rather than a deliberate software failure [9080].
Duration unknown The articles do not mention any software failure incident related to the Chevrolet Volt's battery pack issue. Therefore, the duration of the software failure incident is unknown.
Behaviour crash, value, other (a) crash: The software failure incident in the articles is related to a crash. The crash occurred in the Chevrolet Volt's battery system, specifically after a side-impact crash test. The incident led to a fire in the battery due to an electrical short caused by crystallized coolant, resulting in the battery catching fire weeks after the crash test [54830, 9080]. (b) omission: There is no specific mention of the software failure incident being related to omission in the articles. (c) timing: The timing of the software failure incident is not directly related to the system performing its intended functions too late or too early. The incident occurred weeks after the crash test, indicating a delayed impact rather than a timing issue. (d) value: The software failure incident is related to the system performing its intended functions incorrectly. The incident involved the coolant in the battery system causing an electrical short, leading to a fire in the battery, which is an unintended and incorrect function of the system [54830, 9080]. (e) byzantine: The software failure incident is not described as behaving erroneously with inconsistent responses and interactions in the articles. (f) other: The other behavior of the software failure incident is related to the system losing its intended state and not performing any of its functions correctly due to the crash impact on the battery system, leading to the fire. This behavior aligns with the definition of a crash in software failure incidents [54830, 9080].

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 (property) The software failure incident related to the Chevrolet Volt's battery pack did not result in any real-world fires or harm to individuals. However, there were property-related consequences as seen in the incident where a North Carolina house fire caused $800,000 in damage to a $1.5 million house. Investigators cleared the Volt and its Siemens-manufactured electric charger of starting the fire, indicating that the charger was a victim of the fire, not the cause of it [54830]. Additionally, General Motors considered buying back Volts from concerned owners and promised free loaners to anyone worried about potential fires, showing a financial impact on the company [9080].
Domain transportation, manufacturing The software failure incident reported in the provided articles is related to the transportation industry. The incident involves the Chevrolet Volt's battery pack, which is a crucial component of an electric vehicle designed for transportation purposes. The failure of the battery pack, specifically related to coolant leaks and subsequent fires after crash tests, directly impacts the transportation sector as it affects the safety and reliability of electric vehicles like the Chevrolet Volt [Article 54830, Article 9080].

Sources

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