Robust Design for E-Mobility
Industry Session 28: Reliability
Thursday, March 19, 2020
Autor: Alexander Gerfer
Presented By – Lorandt FölkelWürth Elektronik eiSos GmbH
Sep 2018 TS/AG/TL/sku 2
Can you imagine hiking on a
steep mountain trail in the black
of night not knowing how close
to the edge of the cliff you are?
Would you feel safe?
Quote from ZVEI Handbook
for Robustness Validation
Sep 2018 TS/AG/TL/sku 3
Robust Design for E-Mobility
Reliability is the probability that an electronic component
will perform in accordance with expectations for a
predetermined period of time in a given environment.
Quote from ZVEI Handbook
for Robustness Validation
Sep 2018 TS/AG/TL/sku 4
today tomorrowprivate use
tomorrowshared use
Passenger Car Usage 121.500h( 22,5h per day, 15 years)
Robust Design for E-Mobility
8.000h(1,5h per day, 15 years)
Sep 2018 TS/AG/TL/sku 5
Robust Design for E-Mobility
Having a closer look on the high voltage applications
On-Board Charger InverterBattery
Sep 2018 TS/AG/TL/sku 6
Robust Design for E-Mobility
Tomorrow Shared Use Tomorrow Private Use
No use (DC charging will
be preferred)
up to 22,5h/ day
100.000+ hours
On-Board-Charger
DC-ChargeAC-Charge
DC-DischargeAC-Discharge
Vehicle-2-Grid
Standard Charging
…every time the car is parked
and charging cable plugged in
Sep 2018 TS/AG/TL/sku 7
Robust Design for E-Mobility
Tomorrow Shared Use Tomorrow Private Use
up to 24h/ day
100.000+ hours
up to 24h/ day
100.000+ hours
Battery-Management-System
DC-SupplyDC-Charge
DC-ChargeDC-Discharge
Vehicle-2-Grid /
Regenerative braking
Standard
Charge / Discharge
…whenever car is driving or put
to charge
Sep 2018 TS/AG/TL/sku 10
Robust Design for E-Mobility
What about component
lifetimes?
Sep 2018 TS/AG/TL/sku 11
Robust Design for E-Mobility
approx. 10.000h
Lifetime in average
usage conditions
Lifetime Margin:
-90.000 hours
Aluminium Electrolytic Capacitor
Sep 2018 TS/AG/TL/sku 12
Robust Design for E-Mobility
High Voltage MLCC‘s
How do these components handle the high requirements
concerning vibration, voltage and temperature?
Power Inductors Transformers
Sep 2018 TS/AG/TL/sku 13
Robust Design for E-Mobility
Active comp.
And what about these?
Is AEC-Q100 / 200 the answer??
Electro mechanics PCB’s Assemblies
Sep 2018 TS/AG/TL/sku 14
Robust Design for E-Mobility
ZVEI* Robustness Validation Working Group
Mission Profile
ECU Level
Are AEC-Q
criterias enough?
Determine failure
mechanisms, etc.
Mission Profile
Component Level
Very Critical
Consideration!
Setup Robustness
Validation Plan
If not
ZVEI
Robustness
Validation Group
Source: ZVEI – Handbook for
Robustness Validation* German Electrical and Electronic Manufacturers' Association
Sep 2018 TS/AG/TL/sku 15
Robust Design for E-Mobility
Mission Profile as basis for Robustness Validation
Source: ZVEI – Handbook for
Robustness Validation
Environmental Loads
Interaction
Functional Loads
• Thermal
• Mechanical (e.g. Vibration)
• Radiation
• Dust
• Humidity / Water
• Chemical
• Electromagnetical
• High Speed
• Overtaking / Freuquent Speed
Changes
• Stop & Go
• Mountain Pass
• Trailer Pulling
Assembly Requirements Shipping and Service
Sep 2018 TS/AG/TL/sku 16
Robust Design for E-Mobility
Source of Stress for Electronic Components
The percentages variate for different
applications and packaging locations; Source: ZVEI – Handbook for Robustness Validation
Temperature -Steady State & Cyclical; 55%
Humidity / Moisture; 19%
Contaminants / Dust; 6%
Vibration / Shock; 20%
Sep 2018 TS/AG/TL/sku 17
Robust Design at WE – Pulse Peak
Destructed part by current peaks over the specified value
Example: Input Line Filter
High peak current until capacitor is fully charged SMD
ferrite damage due to peak pulse current possible
Sep 2018 TS/AG/TL/sku 18
Robust Design at WE – Pulse Peak
Withstand Pulse Peak
WE-MPSB, Pulse definition:
Single Pulse 0,5ms – 8ms, 100A max.
Multiple Pulse 8ms 100.000 Pulse max.
Time
Cu
rre
nt
Rated Current
Peak Current
WE-MPSB specification
Size 0805
Sep 2018 TS/AG/TL/sku 19
Robust Design at WE – Pulse Peak
Layer Design:
Special inner silver layer to reach high pulse capability
Sep 2018 TS/AG/TL/sku 20
Robust Design for E-Mobility
Process of releasing a product
Our process is based on 6 fundamental and
properly defined pillars, following the framework of
the APQP principles:
1. Planning: Idea evaluation and project definition
2. Product design and development: Design
phase and prototype elaboration
3. Process design and development: Design
and implementation of the manufacturing line
4. Product and process validation: Pre-launch
phase, process analysis and product
qualification
5. Production: Documentation for production and
release to the market
6. Feedback assessment and correction action:
Continuous improvement to ensure customer
satisfaction
International Standards for Automotive
Certifications
IATF 16949 : 2016
Automotive PPAP (Level 3)
Automation Commitments
Process Capability (Cpk)
Measurement System Analysis (MSA)
Data Tracking (In process and EOL
systems)
IPQC (Control Inspection)
Process Optimization
Product Qualification
Early Validations
AEC-Q200
Stable Automotive Processes
at Würth Elektronik eiSos
Sep 2018 TS/AG/TL/sku
Robust Design for E-Mobility
Total Quality Management
at Würth Elektronik
Measurement Lab
Network/Spectrum/Impedance Analyzers
RF Impedance/Material Analyzer
LCR Bridges with High Current Capability
Precision LCRs
Modular Impulse Generators
Varistor Testers
Winding Testers
ESD Testers
Dielectric and Insulation Resistance
Testers
1000 W Power Supply
300 W Electronic Loads
Environmental Lab
Shock and Vibration
Temperature Cycling
Thermal Shock
Combined Shock and Vibration with
Temperature Cycling Steam Aging
Four Quality Centers
Germany (Waldenburg)
France (Lyon)
China (Longgang)
USA (Watertown)
Analysis Lab
Microscopic Analysis
Cross Sectioning and Polishing
Terminal Strength
Packaging MSL Level Testing
Wetting Balance
RoHS Reflow Profile
Computer Tomography
Hot Air Reflow
Vapor Phase
Wave Soldering
XRF X-Ray
Automatic Pick & Place
Certified according to:
DIN EN ISO 9001, DIN EN ISO 14001, DIN EN ISO
50001, ISO 17025, ISO 17043
Sep 2018 TS/AG/TL/sku 22
Robust Design for E-Mobility
• Factor 10~15 higher requirements concerning component
lifetime coming up
• Significantly higher requirements concerning temperature,
voltage, vibration and EMC
• Some initiatives already started, e.g. ResCar 2.0 Project
Time to Accelerate!
Sep 2018 TS/AG/TL/sku 23
Thank you
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