Bartosz OstrowskiAug 12, 2024 - Interior sensing
Why are Automotive Standards in Electronics Needed?
In an era of ever-increasing vehicle safety requirements and stricter standards, electronics engineers are going head-to-head in producing even more complex systems designed to protect the lives of road users. Components used in the production of automotive electronics must ensure uninterrupted operation of onboard systems, both in terms of moving the vehicle and driver assistance and monitoring systems. Implementing automotive standards in electronics is crucial for ensuring these systems’ reliability, safety, and performance. This blog post will delve into why automotive standards are necessary and explore various aspects, including the consequences of system failures, the role of the Automotive Electronics Council (AEC), and other significant standards that govern the industry.
The Consequences of System Failures
The dangers of system failures in automotive electronics can be dire, leading to both operational and non-operational hazards. Operational hazards occur when a system fails during vehicle operation, potentially resulting in accidents, injuries, or fatalities. For instance, a failure in the electronic stability control system could lead to a loss of vehicle control, especially in adverse driving conditions. Similarly, a malfunction in the braking system’s electronics could prevent the vehicle from stopping in time, causing collisions.
On the other hand, nonoperational hazards arise when a system fails when the vehicle is not in use. This could include issues such as battery drain, which might immobilize the vehicle, or failures in the vehicle’s security system, leading to potential theft. The consequences of these failures underline the importance of robust and reliable electronic components in automotive systems.
The Role of the AEC Qualification
One of the automotive industry’s key certification bodies for electronic components is the Automotive Electronics Council (AEC). The AEC was originally established by Chrysler, Ford, and General Motors with the purpose of creating common part-qualification and quality-system standards. Today, the organization brings together leading manufacturers in the electronics and automotive industries to establish standards that ensure the robustness and reliability of electronic components used in vehicles.
The AEC distinguishes several categories of standards, each addressing different types of electronic components and their specific requirements. These standards include:
AEC-Q100: Failure Mechanism Based Stress Test Qualification for Integrated Circuits
AEC-Q101: Failure Mechanism Based Stress Test Qualification for Discrete Semiconductors
AEC-Q102: Failure Mechanism Based Stress Test Qualification for Discrete Optoelectronic Semiconductors in Automotive Applications
AEC-Q103: Failure Mechanism Based Stress Test Qualification for Sensors in Automotive Applications (Pressure sensors & Microphone devices)
AEC-Q104: Failure Mechanism Based Stress Test Qualification for Multichip Modules (MCM) in Automotive Applications
AEC-Q200: Stress Test Qualification for Passive Components
AEC-Q007: Failure Mechanism Based Testing Guidelines for Components Mounted to a Printed Board
These standards ensure that components are thoroughly tested and qualified to withstand the harsh environmental conditions and operational stresses encountered in automotive applications.
The Importance of Robustness in Automotive Electronics
Automotive electronics are subjected to a wide range of environmental conditions, including extreme temperatures, humidity, vibration, and electromagnetic interference. The robustness of these components is critical to their performance and reliability. For instance, integrated circuits (ICs) used in automotive applications must be able to operate reliably across a temperature range from -40°C to 125°C or even higher in some cases. This requires rigorous testing and qualification to ensure the ICs can handle these conditions without failure.
Moreover, automotive electronics must be able to withstand mechanical stresses such as vibration and shock. Vehicles are subjected to constant movement and impacts, which can cause physical damage to electronic components if they are not properly designed and tested. The AEC standards include specific tests to evaluate the mechanical robustness of components, ensuring that they can endure the rigors of automotive use.
8-D analysis
When a vehicle includes a defective AEC-qualified component, the manufacturer must work with their customer to perform an 8-D analysis (see, e.g., [1, 2]) and apply preventive measures to resolve the issue. This process involves identifying the root cause of the failure, implementing corrective actions, and taking steps to prevent similar issues in the future.
Preventive measures can include design changes, process improvements, and additional testing to verify the effectiveness of the implemented solutions. By taking these steps, manufacturers can reduce the likelihood of component failures and enhance the overall reliability of automotive electronics.
Additional Automotive Standards
Beyond AEC, several other standards play crucial roles in ensuring the reliability and safety of automotive electronics. These include IATF 16949, SN 29500, IEC 62308, ISO 26262, and the Automotive Safety Integrity Level (ASIL) [2].
IATF 16949
IATF 16949 is an international standard for quality management systems specifically designed for the automotive industry. It was developed by the International Automotive Task Force (IATF) in conjunction with the International Organization for Standardization (ISO). The standard aims to improve product quality and ensure the reliability of automotive components and systems.
Applications and Scope:
Quality Management: IATF 16949 encompasses a wide range of quality management principles, including risk management, supplier management, and process control.
Continuous Improvement: It emphasizes the importance of continuous improvement and defect prevention.
Supplier Relationships: The standard also focuses on building strong relationships with suppliers to ensure quality throughout the supply chain.
SN 29500
SN 29500 is a standard developed by Siemens for predicting the reliability of electronic components. It provides guidelines for evaluating the reliability of electronic components used in various applications, including automotive. The standard includes methods for calculating failure rates and predicting the reliability of components based on factors such as operating conditions and environmental stresses.
Applications and Scope:
Reliability Prediction: SN 29500 helps manufacturers assess the reliability of their electronic components and identify potential failure modes.
Design Enhancement: By using this standard, manufacturers can design more robust systems and implement preventive measures to mitigate the risk of failures.
IEC 62308
IEC 62308 is an international standard that provides guidelines for the reliability of electronic systems and components. It covers various aspects of reliability, including design, testing, and maintenance. The standard emphasizes the importance of reliability engineering in the design and development of electronic systems.
Applications and Scope:
Reliability Assessment: IEC 62308 includes methods for assessing the reliability of electronic components and systems.
Testing and Evaluation: It provides guidelines for conducting reliability tests and evaluations.
Maintenance: The standard also covers aspects of maintenance to ensure long-term reliability.
ISO 26262 and Automotive Safety Integrity Level (ASIL)
ISO 26262 is an international standard for the functional safety of electrical and electronic systems in road vehicles. It provides a comprehensive framework for ensuring the functional safety of automotive systems and components throughout their lifecycle, covering various aspects such as risk assessment, hazard analysis, and safety validation.
Applications and Scope:
Functional Safety and ASIL: A key concept introduced by ISO 26262 is the Automotive Safety Integrity Level (ASIL), which classifies the safety requirements of automotive systems based on the severity, exposure, and controllability of potential hazards. ASIL levels range from ASIL A (lowest safety requirement) to ASIL D (highest safety requirement).
Safety Lifecycle: The standard encompasses the entire safety lifecycle, from concept to decommissioning, ensuring that safety is integrated at every stage.
Hazard Analysis and Risk Management: ISO 26262 includes guidelines for conducting thorough hazard analysis and risk assessments. The ASIL classification aids manufacturers in identifying the safety requirements of their systems and implementing appropriate measures to achieve compliance.
Hierarchy and Interrelationship of Standards
Understanding the hierarchy and interrelationship of these standards is essential for manufacturers aiming to achieve comprehensive compliance and enhance the reliability and safety of their automotive electronics.
Hierarchical Structure
ISO Standards: ISO 26262 and IATF 16949 are overarching standards that provide a broad framework for functional safety and quality management. They set the stage for more specific standards.
AEC Standards: Within this framework, AEC standards such as AEC-Q100 to AEC-Q200 focus on the qualification and reliability of specific electronic components.
Supplementary Standards: Standards like SN 29500 and IEC 62308 provide additional guidelines and methods for reliability prediction and assessment, complementing the AEC standards.
Interrelationship and Application
ISO 26262 and ASIL: These standards guide the overall safety lifecycle and safety integrity levels, influencing the design and development processes to ensure functional safety.
IATF 16949: This standard ensures that quality management principles are integrated throughout the manufacturing process, influencing supplier relationships and continuous improvement practices.
AEC Standards: These standards ensure that individual components meet specific reliability and robustness criteria, aligning with the broader safety and quality requirements set by ISO 26262 and IATF 16949.
SN 29500 and IEC 62308: These standards provide detailed methods for reliability prediction and assessment, supporting the implementation of AEC standards and enhancing the overall reliability of electronic components and systems.
Practical Applications and Industry Impact
The application of these standards is widespread across various segments of the automotive industry. Each standard plays a crucial role in different stages of the automotive electronics lifecycle, from design and development to manufacturing and maintenance.
Design and Development
ISO 26262 and ASIL: During the design and development phase, engineers use ISO 26262 to conduct hazard analysis and risk assessments, determining the ASIL for different systems. This process helps in designing systems with the appropriate safety measures to mitigate risks.
AEC Standards: Engineers also refer to AEC standards to select and qualify electronic components that meet the necessary robustness and reliability requirements.
Manufacturing
IATF 16949: In the manufacturing phase, IATF 16949 ensures that quality management systems are in place. This includes supplier quality management, process control, and continuous improvement practices to produce high-quality automotive electronics.
SN 29500 and IEC 62308: These standards help in predicting the reliability of components and systems, enabling manufacturers to implement preventive measures and improve product reliability.
Maintenance and Aftermarket
IEC 62308: This standard provides guidelines for the maintenance of electronic systems, ensuring their long-term reliability and performance. Regular maintenance and reliability assessments help in identifying potential issues before they lead to failures.
ISO 26262: During the aftermarket phase, ISO 26262 ensures that any modifications or updates to the vehicle’s electronic systems maintain the required safety levels. This includes re-evaluating the ASIL and conducting necessary safety validations.
Future Trends in Automotive Electronics Standards
As automotive technology continues to evolve, the standards governing automotive electronics must also be adapted to address new challenges and opportunities. Emerging trends such as electric vehicles (EVs), autonomous driving, and connected car systems are shaping the future of automotive standards.
Electric Vehicles (EVs)
The transition to electric vehicles introduces unique challenges for automotive electronics, including the need for high-voltage components, advanced battery management systems, and efficient power electronics. Standards such as AEC-Q200, which focuses on passive components, will be essential in ensuring the reliability of these systems. Additionally, new standards may be developed to address the specific requirements of EVs, such as high-voltage insulation and thermal management.
Autonomous Driving
Autonomous driving systems rely heavily on advanced sensors, processing units, and communication modules. The AEC-Q103 standard for sensors and the AEC-Q104 standard for multichip modules will be critical in ensuring the reliability of these components. As autonomous driving technology advances, new standards will likely be needed to address the complexities and safety requirements of fully autonomous vehicles.
Connected Car Systems
Connected car systems, which enable vehicles to communicate with each other and with infrastructure, require reliable and secure electronic components. Standards for electromagnetic compatibility (EMC) and cybersecurity will be crucial in ensuring the integrity and reliability of connected car systems. The AEC and other standards organizations will need to collaborate to develop and update standards that address the evolving requirements of connected car technology.
Conclusion
The implementation of automotive standards in electronics is essential for ensuring the reliability, safety, and performance of modern vehicles. The rigorous testing and qualification processes defined by organizations like the Automotive Electronics Council, ISO, IEC, and IATF play a critical role in ensuring that electronic components can withstand the harsh conditions encountered in automotive applications. By adhering to these standards, manufacturers can reduce the likelihood of system failures, enhance vehicle safety, and build consumer trust.
As automotive technology continues to advance, the development and updating of standards will be crucial in addressing new challenges and ensuring the continued reliability of automotive electronics. From electric vehicles to autonomous driving and connected car systems, standards organizations will play a vital role in shaping the future of automotive technology and ensuring the safety and reliability of the vehicles we rely on every day.
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References
[1] https://asq.org/quality-resources/eight-disciplines-8d. Access date: 22.07.2024.