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Electrical Vehicle (EV) is believed to be the new generation of automobile. EIC system of EV includes battery, electronic control and motor, which shows great impact of industrial development. To improve charging efficiency and increase output power of motors, manufacturers continually enhance the product specification for "high power", however it accompanies with several reliability problems such as product heating. Additionally, along with the trend of driverless car, edge computing, also known as high computing component, is under developing as well. The key issues raised by the high speed of computing include the method to install server in the car, the solution of heat and product reliability problems.

Wangchu Chen, the senior manager of DEKRA iST, was invited to share “The Challenges of Next Generation for High Power/High Computing Component suppliers in Smart Electric Vehicle beyond EIC system” in Electric Mobility Future Seminar which was held on April 22nd in Nangang Exhibition Hall by TAITRA and EETimes. Through prerecorded video, Wangchu analyzed the needs and challenges of smart EV industry and earned great responses from the audience.


The Trend of All-in-one Products in EV Industry
Wangchu started his speech from analyzing the three core components of EV include battery, electronic control and motor. Among them, motor is the key component of EV, and couple of Taiwanese manufacturers have their own technology and would like to jump into the motor supply chain of EV. Key competences of motor are light, powerful and quiet features. The trend of EV development focuses on the integration of components, such as two-in-one product of OBC and DCDC converter in the electronic control, the integration of reducer (known as generator) and the inverter in the motor. Moreover, the main market and technology in the future is believed to be all-in-one products, which feature lighter weight, lower power consumption and higher mileage. However, there’re still some disadvantages of all-in-one products like the higher cost of entire module replacement for maintenance. Overall, the trend of the final product development will still be determined by the market.

In the market, the advantages of EV include less CO2 emission, lower cost of fuel and brand value, etc., while there’s one more issue catches everyone’s eyes, the integration of driverless technology and EV. As the concept of all-in-one product above, for driverless technology, numerous sensors are installed in EV, and the signals received by the sensors will be transmitted to AI(Artificial Intelligence) through the connector for calculation, which is one of the key points of this speech, high computing component in EV.

Power System and Reliability Validation of EV
There are two modes of power transmission from charger to EV, one is to transmit power from charger to the batteries in EV after AC is converted to DC, and the other is to transmit AC to the onboard charger in EV directly, and AC will be converted to DC for batteries. Then, the output of batteries will supply power for motor through DC/AC inverter, and also supply power to other automotive components through DC/DC converter.


Therefore, when it comes to reliability validation, it is necessary to consider both output and input of AC and DC separately. DEKRA iST has built up a comprehensive tests and complete equipment system, including AC/DC Source, AC/DC Load, water cooling system, and recorder to record the complete test parameters for all-in-one products. The tests include dynamic stress (Mechanical Loads), climatic stress (Climatic Loads), material stress (Material Verification) and electrical verification (Electrical Loads), etc.




Prediction of Product Life and Validation of High-power Component
The product life of fossil fuel vehicle is mainly estimated by the total length of engine on time and engine off time, while the product life of EV is more complicated due to the consideration of charging time and inhabited time. It would probably become even more complex when it comes to driverless technology with much higher power consumption during continual operation. In conclusion, the trend of high-power components is unstoppable, and the concepts and methodologies of reliability validation should be caught up simultaneously to ensure the quality of products and the safety of end customers.

High-power components in EVs include IGBTs (Insulated Gate Bipolar Transistors). DEKRA iST also provides comprehensive validation for compound semiconductor. Through the collection and thermal calculation of driving profile with specific equipment and the method of IOL (Intermittent Operational Life), we could help our clients to verify the life cycle of products.

More details of IOL (Intermittent Operational Life): <he Crux of WBG Component in Global Green Revolution>



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