As EVs become more complex and feature-rich for the consumer, mass adoption can drive down costs as EVs are built at scale. While battery costs continue to decline, the same trend is expected for an EV’s electronics. However, this transition will not be without its challenges as the industry undergoes massive changes.
In light of this evolving landscape, several key issues must be addressed:
- Cost: EVs have more advanced and complex electronics than conventional vehicles, making manufacturing more expensive. EV Original Equipment Manufacturers (OEMs) must find ways to reduce the cost of manufacturing these electronics while maintaining high-quality standards.
- Supply Chain: The expanding EV market has created a complicated supply chain for automotive electronics. Numerous automakers are now partnering with Electronic Manufacturing Service (EMS) providers, who have primarily focused on consumer electronics production in the past. This shift necessitates EMS providers to embrace automotive practices such as the Production Part Approval Process (PPAP) and Advanced Product Quality Planning (APQP), vital for meeting customer demands, adhering to quality standards, and maintaining regulatory compliance, among other aspects. Some EMS providers, for instance, are finding it challenging to guarantee that incoming materials meet the stringent quality requirements for automotive manufacturing, as this differs significantly from the mindset applied to consumer electronics production.
- Quality Control: EV OEMs must maintain strict quality control measures to ensure that the manufactured electronics meet the highest reliability and safety standards. Failure to do so could result in costly product recalls and damage the brand’s reputation. In addition, the global labor shortage in electronics manufacturing and the relative inexperience of many new entrants to the automotive sector exacerbate this challenge.
- Reliability: EV electronics are anticipated to have extended mission profiles or duty cycles, necessitating increasingly powerful processors and power electronics. This can generate substantial heat, potentially reducing the lifespan of electronic components if not properly managed. When incorporating new features, designers must consider the overall design’s reliability, considering factors such as the effects on other systems, costs, and component quality.
- Testing and Certification: It is crucial to ensure that automotive electronics meet regulatory and safety standards through testing and certification. However, as innovative electronic technologies rapidly emerge, traditional manufacturing standards designed for primarily mechanical vehicles face challenges in adapting. This is due to the automotive industry’s focus on proven, mainly mechanical, and relatively simple electronic technologies for over a century. As EVs increasingly rely on advanced electronics, collaboration among various standards organizations becomes essential. The involvement of multiple organizations in this field, as illustrated in the table below, highlights the need for cooperation. This collaboration will contribute to the development of relevant and effective standards and regulations, ensuring the safety and reliability of EV electronics.
- Recalls: Currently, EVs experience more recalls than conventional vehicles, mainly due to the challenges mentioned earlier. As market demand drives increased EV adoption and production, these vehicles might continue to face disproportionate recalls. Over-the-air updates (OTA) have limitations in addressing all issues, as fixing coding errors is quite different from addressing hardware failures.
Collaboration for a Brighter Future in e-Mobility
The increasing role of electronics in electric vehicles presents significant opportunities and challenges for both the automotive and electronics sectors, emphasizing the need for collaboration and adaptability. The electronics industry must lead in driving this change, transitioning from a predominantly “consumer electronics” mindset, prevalent among many current EV suppliers, to a more methodical automotive approach that satisfies consumer demands without sacrificing quality and dependability. Amidst these rapid advancements, it is essential to remember that an electric vehicle’s primary purpose is to transport passengers safely.
The e-Mobility Quality & Reliability Advisory Council of IPC ensures that the electronics industry, automotive OEMs, and suppliers tackle the numerous challenges outlined in this article. By collaborating, these stakeholders can create solutions that uphold high quality, safety, and reliability standards while catering to consumer expectations for innovative and advanced features in electric vehicles.
Some of the tasks undertaken by the advisory council include:
- Identifying gaps in standards, whether within IPC or other automotive-focused organizations.
- Establishing a knowledge repository for easy access by all stakeholders.
- Providing educational services to retrain and keep up with the rapidly evolving industry.
In conclusion, the growing prominence of electronics in electric vehicles poses challenges and opportunities for the automotive and electronics industries. By acknowledging the importance of this trend and working together to tackle the intricate issues it presents, these industries can ensure that electric vehicles continue to evolve and improve, offering innovative and advanced features while maintaining the highest standards of quality, safety, and reliability. The e-Mobility Quality & Reliability Advisory Council of IPC and other organizations are clearing the path for the industry to reach these objectives, guaranteeing a bright and sustainable future for electric vehicles and those who depend on them.
Organizations involved in Automotive Electronics
Progress and Impact on Core Functions
The Essential Role of Power Electronics in Electric Vehicles
