Published May 3, 2023 | Version v1
Journal Open

Reliability and Safety Assessment of Automotive Power Electronics

Authors/Creators

Contributors

Description

Automotive power electronics are critical components in modern vehicles, particularly in electric and hybrid electric vehicles, where they control and convert electrical energy to drive motors efficiently. The increasing demand for higher performance, compactness, and energy efficiency has exposed these systems to severe thermal, electrical, and mechanical stresses, which can compromise their reliability and safety. This study presents a comprehensive assessment of the reliability and safety of automotive power electronics, focusing on the identification of common failure mechanisms, prediction of component lifetimes, and evaluation of system-level fault tolerance. Reliability modeling techniques, including statistical analysis, physics-of-failure approaches, and accelerated life testing, are employed to quantify the expected performance over operational lifetimes. Safety assessment is conducted using fault tree analysis, hazard and risk analysis, and compliance evaluation against relevant automotive safety standards such as ISO 26262. The results highlight critical failure modes, their potential impact on vehicle operation, and strategies to enhance system robustness and safety. The study provides valuable insights for designers, engineers, and researchers aiming to optimize automotive power electronics for reliable and safe operation under real-world conditions.

Files

relibility.pdf

Files (364.4 kB)

Name Size Download all
md5:dc7aeebdf16f7112baa343e290abcf71
364.4 kB Preview Download

Additional details

Dates

Issued
2023-05-03

References

  • 1. Pimpale, S. (2021). Impact of Fast Charging Infrastructure on Power Electronics Design. International Journal of Research Science and Management, 8(10), 62-75.
  • 2. Cherfi, A., Leeman, M., Meurville, F., & Rauzy, A. (2014). Modeling automotive safety mechanisms: A Markovian approach. Reliability Engineering & System Safety, 130, 42–49. This paper discusses modeling approaches for safety mechanisms in automotive electronic systems under ISO 26262, illustrating how safety measures contribute to functional safety. AltaRica Association
  • 3. Mahmood, A., & Szabolcsi, R. (2025). A systematic review on risk management and enhancing reliability in autonomous vehicles. Machines, 13(8), 646. Reviews risk management strategies and reliability considerations in autonomous vehicle systems, relevant for power electronics reliability frameworks. MDPI
  • 4. Sinha, P. (2011). Architectural design and reliability analysis of a fail operational brake by wire system from ISO 26262 perspectives. Reliability Engineering & System Safety, 96(10), 1349–1359. Explores design and analysis of safety critical automotive systems using ISO 26262 guidelines (fail operational context). ResearchGate
  • 5. Reliability challenges of automotive power electronics. (2009). Microelectronics Reliability, 49(9–11), 1319–1325. Describes the main reliability challenges associated with automotive power electronic modules, particularly under thermal and operational stresses. ScienceDirect
  • 6. Ismail, A., Qiang, L., & Jung, W. (2014). ISO 26262 automotive functional safety: Issues and challenges [Unpublished manuscript]. Discusses the complexity and application of ISO 26262 for automotive electronic systems and the importance of detailed safety analyses for electrical and electronic components. ResearchGate
  • 7. Failure mode and effect analysis based on electric and electronic architectures of vehicles to support the safety lifecycle ISO/DIS 26262. (2011). IEEE Conference Publication. Provides insight into the application of FMEA within the ISO 26262 safety lifecycle to identify risks in electric/electronic architectures of vehicles. IEEE Xplore
  • 8. Understanding ISO 26262. (n.d.). In Wikipedia. Provides an overview of the ISO 26262 functional safety standard, its structure, and its role in automotive electrical/electronic system safety
  • 9. Pimpale, S. (2021). Impact of Fast Charging Infrastructure on Power Electronics Design. International Journal of Research Science and Management, 8(10), 62-75.
  • 10. DeVoto, D. (2023). Thermomechanical reliability aspects of automotive power electronics: Current status and future trends [Conference presentation]. IEEE Applied Power Electronics Conference (APEC). Discusses common failure mechanisms in automotive power electronics packaging and approaches to improve mechanical reliability. Research Hub
  • 11. Falck, J., Felgemacher, C., Rojko, A., Liserre, M., & Zacharias, P. (2021). Reliability of power electronic systems: An industry perspective. CORE. Provides an industry survey of stressors and failure mechanisms affecting power electronics across applications, including EV systems. CORE
  • 12. Farhadi, M., Vankayalapati, B. T., Sajadi, R., & Akin, B. (2023). AC power cycling test setup and condition monitoring tools for SiC based traction inverters. arXiv. Describes realistic power cycling tests and condition monitoring tools for evaluating reliability in high power automotive converters. arXiv
  • 13. Rezaeizadeh, A., Zardini, G., Frazzoli, E., & Mastellone, S. (2023). Reliability aware control of power converters in mobility applications. arXiv. Introduces control strategies that include reliability modeling to mitigate thermal stress in automotive power converters. arXiv
  • 14. Naruman¬chi, S., Bennion, K., Cousineau, E., Feng, X., & Major, J. (2017). Thermal management and reliability of automotive power electronics and electric machines (NREL Report No. NREL/PR 5400 70156). National Renewable Energy Laboratory. Offers insights into thermal stress effects and design considerations for improving module reliability. NREL
  • 15. Rodriguez, et al. (2019). A methodology to determine reliability issues in automotive SiC power modules combining 1D and 3D thermal simulations under driving cycle profiles. Microelectronics Reliability, 102, 113500. Presents an electro thermal modeling approach for identifying reliability challenges in SiC modules. ScienceDirect
  • 16. ISO 26262. (n.d.). In Wikipedia. Overview and summary of the automotive functional safety standard, its scope, and key safety lifecycle requirements for electronic systems. Wikipedia
  • 17. Monolithic Power Systems. (n.d.). Safety and compliance standards in automotive electronics. Discusses the role of reliability and safety standards in automotive electronic design. Monolithic Power Systems
  • 18. Siemens Software. (n.d.). Automotive power electronics – accurately predict field reliability. White paper on methods for characterizing and improving power electronics reliability under high load conditions. Siemens Resource Center