Mitigation of Sensor-Level Cyber-Physical Attacks on Electric Vehicle Powertrains: A Simulation-Based Study

Electric vehicles (EVs) rely extensively on sensor feedback for safe and efficient powertrain operation. However, this dependency introduces cyber-physical vulnerabilities, especially when sensor signals are maliciously manipulated. This paper presents a simulation-based investigation into sensor-level cyberattacks on a mid-sized EV powertrain model developed in MATLAB/Simulink. The study quantifies mechanical consequences and evaluates mitigation strategies to enhance system resilience. Four representative attack scenarios were simulated. Speed sensor spoofing led the controller to misinterpret vehicle velocity, causing a 41% overshoot beyond the 50 km/h setpoint. False data injection into torque/current sensors triggered an unintended torque surge of approximately 20%, resulting in inverter current saturation within 2 seconds. Battery temperature spoofing delayed thermal protection, allowing a deviation of 1.5 °C/min beyond safe operating limits. A hybrid attack combining frozen speed feedback with a forced 100% throttle input caused runaway acceleration and actuator saturation lasting over 10 seconds. These scenarios demonstrate how localized sensor attacks can propagate through control loops, destabilizing vehicle dynamics. To counter these threats, we implemented signal plausibility checks, observer-based anomaly detection, and fail-safe torque limiting. These measures collectively reduced overshoot by more than 50% in spoofing cases. Beyond simulation, we propose a multi-layered defense framework incorporating cross-sensor validation, statistical and machine learning-based anomaly detection, secure communication protocols (ISO/SAE 21434), signal-level defenses, and conservative fallback controls. By linking cyber intrusions to tangible mechanical instabilities and validating countermeasures through simulation, this work offers actionable insights for engineers developing robust and secure EV powertrains. It underscores the necessity of integrating mechanical and cybersecurity disciplines to ensure the safety and reliability of future electric mobility systems.