Route-Aware AI-Assisted Fault Diagnosis and Fault-Tolerant Energy Management for Hybrid Hydrogen Electric Vehicles: SIL and PIL Validation

This paper proposes a unified energy management, fault detection, and fault-tolerant control (EMS–FDI–FTC) framework for Hybrid Hydrogen Electric Vehicles (HHEVs) integrating a fuel cell (FC), battery (Bat), and supercapacitor (SC). While such multi-source architectures enable high-efficiency propulsion under dynamic driving conditions, actuator and state faults such as FC voltage sag, Bat internal resistance increase, and SC capacitance degradation can compromise safety, availability, and component lifetime. The proposed framework converts real-world GPS-recorded vehicle speed profiles into route-aware traction power demand and combines interpretable model-based indicators with an AI-based fault detection and classification module. Based on the diagnosis outcome, a fault-tolerant supervisory strategy performs online power reallocation among the FC, Bat, and SC while enforcing operational constraints. Validation is conducted in a MATLAB-based software-in-the-loop (SIL) environment using three urban driving routes collected from on-road measurements in Tunisia with injected ground-truth faults. The results demonstrate reliable fault classification performance and effective service continuity during fault intervals, supplying over 94% of the demanded energy across all routes, with energy-not-served remaining below 0.02 kWh. In addition, processor-in-the-loop (PIL) implementation on an STM32F407VG controller confirms real-time feasibility with a 10 Hz supervisory sampling rate and execution time margins compatible with embedded automotive deployment. Overall, the proposed closed-loop framework provides a practical route-aware diagnosis-to-control solution for robust and fault-resilient HHEV operation under realistic driving variability. All energy and efficiency indicators reported in this study are derived from control-oriented component models and are intended for consistent comparative evaluation across routes and operating scenarios, rather than absolute representation of a specific commercial vehicle.