Analysis of failures due to Ant entry in Automotive Electronic Components and integration of learnings in design

Automotive electronic components are exposed to different environmental conditions and these conditions may impact on the functioning of the components, leading to failures in vehicles globally. These failures often create inconvenience for the customers across OEMs. Addressing the failures requires measures that incur extra costs. One of the environmental factors is insect entry inside the components. This Quality research paper aims to address the need of revision of design standards due to failures caused by Ant entry. The increase in integration of technology in vehicles has led to an increase in the use of electronic components such as switches, control modules, and controllers. Vehicles are often parked in open areas (under trees, open grounds, basements or construction sites), and are in close vicinity to Ant nests or feeding areas. Ants are drawn to the warmth and shelter provided by vehicle engine bays and wiring compartments. In some cases, especially in tropical regions, ants have been found nesting inside electrical enclosures, fuse boxes, and connectors. Ant entry eventually results in-to failures such as short circuits, and open circuits. A study was conducted on the failed parts received from the market and the head sizes of the ants were measured through magnification. It was determined that the smallest head size of the ant was X mm which gave direction to us for finalizing maximum allowed clearances in a part. However, there are some of the parts which still need higher clearances for which guidelines are laid down to protect the electronic components from Ant entry-related failures. This data gave us a new perspective to revise the design standards & can also enable other OEMs to better understand the unique market problems & take necessary action for Ant entry-related failures.