Method for Preliminary Assessment about Lifetime Estimation of Electronic Components in Hybrid and EV Applications

Increasing demand of Electric and Hybrid vehicles questions more about Reliability and Lifetime of electronic circuits associated with them. It is very important for a hardware circuit designer to evaluate if module will last the expected lifetime. This paper elaborates the methods and steps to find the expected lifetime of critical components; and to decide whether Hybrid Power Electronics Unit (PEU) will meet the OEM requirements on lifetime. Accelerated thermal stress method is used to determine the required High Temperature Operational Life (HTOL) hours for given thermal profile of Hybrid vehicle passenger car in driving (8,000Hrs), charging(30,000Hrs) and total lifetime (38000Hrs ≈ 15Years). Example calculation of required HTOL hours against expected lifetime for critical component from Hybrid ECUs is explained in this paper. Also inclusions and exclusions of this method in evaluating lifetime assessment are also discussed here.

Stepwise method explained in paper helps in taking preliminary judgment of components regarding lifetime and sort out thermally critical components so as to take corrective actions together with components manufacturer.