Enhancing electric vehicle range through real-time failure prediction and optimization: Introduction to DHBA-FPM model with an artificial intelligence approach

Electrical and mechanical failures in electric vehicles (EVs) during passenger operation cause significant operational losses and elevated energy consumption, amplifying range anxiety. To address this issue, we utilized 250,000 rows of real-time data from electric trolleybuses operating in Türkiye to develop a robust artificial intelligence (AI)-based optimization model for failure mitigation. Initially, Tri layered Neural Network (TNN) was employed to create a predictive function for electrical and mechanical failures, followed by comparative analyses across six optimization algorithms widely adopted in failure prediction studies. Among these, the Developed Honey Badger Algorithm with AI Approach (DHBA) emerged as the most effective, achieving a predictive accuracy improvement of 15 % over the standard Honey Badger Algorithm (HBA). The DHBA incorporates a Dynamic Fitness-Distance Balance (DFDB) mechanism and a novel spiral motion feature to enhance search precision, leading to the DHBA-FPM (Developed-Honey Badger Algorithm - Failure Prediction Model). The final DHBA-FPM model was applied to the 10 highest-density bus routes in Türkiye to predict and optimize failures. Results indicate that applying the DHBA-FPM model across these routes yielded a 3.96 % average range increase in EVs, extending the total range by approximately 79,200 km annually. It can be concluded that the model could prevent the release of 238.7 tons/year of CO₂, NO, and NO₂ emissions through its potential to improve both the operational efficiency and sustainability of EVs in public transit networks.