Modern vehicles are increasingly reliant on control units. While a moderately equipped car manufactured after 1980 contained around 20 control units, today's vehicles typically have more than 200. Due to this trend, modern vehicles are becoming more dependent on printed circuit boards (PCBs). As PCBs serve as the nervous system of modern cars, it is essential to adhere to safety standards. It is anticipated that with further technological advancements, the demand for PCBs in the automotive industry will continue to grow.In this article, we will discuss the requirements for automotive PCBs, outline the standards for automotive PCBs, and explain why it is beneficial to use AS9100D-certified PCBs in the automotive industry.
The integration of electronics into vehicles has introduced many challenges for PCB design. Quality, precision, and compact size have become priorities in automotive PCB design. Unsurprisingly, the design, manufacturing, and functionality of automotive PCBs are governed by specific requirements and strict standards. Understanding these standards is fundamental to ensuring the safety, reliability, and optimal performance of vehicles.
This standard specifies Quality Management System requirements for companies that design, develop, or manufacture aerospace, space, and defense products. As a result, this standard not only encompasses the requirements of ISO 9001 but also identifies additional requirements for the aerospace, space, and defense industries. This includes, for example, added focus on handling counterfeit parts, attention to the human factor in manufacturing quality, a focus on product safety, ethical training, and a process approach including SIPOC and PDCA management methods, risk-based thinking, and monitoring supplier delivery performance. Using AS9100D-certified PCBs is particularly suitable for safety-critical automotive applications.
Several critical environmental factors affect automotive PCBs. We will discuss ensuring durability and reliability in extreme conditions, the impact of thermal management on material selection, and the effects of temperature fluctuations, vibrations, and shocks. Each of these factors can significantly influence the quality and performance of automotive PCBs.
Durability and Reliability in Extreme Conditions
It is no surprise that automotive PCBs are exposed to extreme conditions. To maintain the required durability and reliability, a specific approach must be taken during both design and subsequent manufacturing. Designers should consider increased vibrations and impacts, thermal fluctuations, and more. This involves incorporating reinforced construction, innovative thermal solutions, and other measures. Thorough testing should not be overlooked, and it should include testing for thermal cycles, vibration tests, etc.
When you have a PCB suitable for automotive applications, it is essential to manufacture it properly. With AS9100D-certified PCBs, you don't have to worry about quality issues.
In the increasingly interconnected and electronic environment of modern vehicles, seamless integration of various electronic components is paramount. Components such as sensors, control units (ECUs), and others that rely on PCBs must coexist harmoniously to ensure the vehicle operates correctly. The need for seamless integration underscores the importance of addressing electromagnetic compatibility (EMC) issues. EMC ensures that the numerous electronic systems within a vehicle can operate simultaneously without harmful interference.
Compliance with EMC standards is a critical element in preventing electromagnetic interference (EMI), which can disrupt the operation of electronic systems within the vehicle. EMI occurs when unwanted electromagnetic signals interfere with the normal functioning of electronic components. Compliance with EMC standards sets guidelines and limits for electromagnetic emissions and sensitivity, creating a framework for the compatibility of various vehicle systems. This compliance not only prevents internal component interference but also protects against external sources of interference, such as radio frequencies or other electronic devices in the vehicle.
Since selecting PCB materials for automotive use is critical, several aspects must be considered.
Compliance with environmental regulations should not be based solely on legal obligations. Any sustainable business should voluntarily adhere to these regulations, as they are crucial for supporting safety, environmental protection, and sustainability in the automotive electronics industry.
Simulate Real-World Conditions to Ensure Long-Term Reliability
Purpose: The PCB is subjected to repeated cycles of temperature changes that simulate extreme thermal conditions in a real automotive environment. This test is essential for assessing the PCB's ability to withstand temperature fluctuations without compromising functionality or structural integrity.
Procedure: The PCB is exposed to alternating cycles of high temperatures, typically ranging from -40°C to 125°C or higher. The number of cycles and the rate of temperature change depend on specific requirements and regulatory standards.
Purpose: The PCB's response to sudden drastic temperature changes, which simulate conditions such as rapid cooling or heating during vehicle operation. Successfully completing this test indicates that the PCB can withstand sudden temperature changes without failing.
Procedure: The PCB undergoes rapid transitions between extremely high and low temperatures. This process evaluates the thermal stress's impact on the material and solder joints, revealing potential weaknesses.
Purpose: This test simulates the mechanical vibrations and shocks that occur during vehicle operation. The goal is to identify and eliminate weaknesses in the design or manufacturing that could lead to failures under vibrational stress.
Procedure: The PCB is subjected to controlled levels of vibrations that mimic road conditions and vehicle motion. The test is conducted in multiple orientations to evaluate the PCB's structural integrity and the reliability of solder connections and components under stress.
Purpose: This test ensures the PCB's electromagnetic compatibility (EMC) and its resistance to electromagnetic interference (EMI). Testing is conducted in an environment with various electronic devices and systems to identify potential sources of interference.
Procedure: The PCB is placed in an environment with various electronic devices and systems. Measurements are taken to ensure the PCB emits only acceptable levels of electromagnetic radiation and is not susceptible to interference from other sources.
Purpose: The goal of this test is to assess the PCB's ability to resist moisture, which can lead to corrosion or electrical shorts.
Procedure: The PCB is exposed to high humidity and moisture levels. After exposure, it undergoes functional tests to ensure that moisture has not compromised its performance.
Rigorous testing of automotive PCBs demonstrates that durability and long-term reliability are primary goals in the automotive industry. To achieve high-quality PCBs for automotive applications, consider using AS9100D-certified boards. These boards, designed for the aerospace, space, and defense industries, meet even stricter conditions, making them highly suitable for the automotive sector.
Vehicles often remain in operation for well over ten years. The availability of replacement parts, including PCBs, is crucial for maintaining such vehicles. Besides maintenance, another key reason for long-term availability of replacement parts is ensuring modernization and reliability throughout the vehicle's lifespan.
Collaboration with suppliers relies on open communication. This helps anticipate potential availability issues, allowing proactive measures like securing alternatives or stockpiling critical components.
When designing PCBs, think ahead to ensure the board allows for the installation of alternative or compatible components. This will maintain a continuous supply chain even as technology evolves.
Choose suppliers who can guarantee the long-term supply of components. This includes selecting materials and technologies with long-term availability and minimizing dependence on those prone to obsolescence. If necessary, formalize these agreements contractually.
Adhere to regulations. The automotive industry is heavily influenced by strict regulatory requirements. To demonstrate compliance with standards, traceability must be ensured. Traceability also allows manufacturers to provide detailed documentation for audits and certifications.
In comprehensive product lifecycle management, traceability is essential, enabling the tracking of component performance, predicting maintenance needs, and planning for upgrades or replacements.
Each component must be traceable back to its production batch, facilitating effective quality control. This ensures traceability. In the event of a defect or other issue, traceability helps identify the root cause, enabling targeted improvements in the manufacturing process. Tracking can be ensured through serial numbers or barcodes, which are excellent identifiers for PCBs. These identifiers allow the PCB to be tracked throughout its entire lifecycle.
Traceability helps manufacturers and service providers quickly identify affected components and take corrective actions, minimizing downtime and ensuring vehicle safety. Comprehensive traceability can only be achieved by maintaining detailed records of manufacturing data, test results, and any modifications made to the PCB post-production, perhaps through an enterprise information system. Collaboration platforms integrated with supply chain partners enable real-time tracking and traceability across the entire production chain.
The automotive industry is undergoing a significant transformation, placing more emphasis on PCB quality than ever before. This is particularly important given that a modern car comprises approximately 200 electronic control units, accounting for around 10,000 PCBs that must be reliable.
Safety, reliability, and consistent performance in the dynamic environment of the automotive industry are ensured by standards like ISO 26262, IPC-6012DA, and AEC-Q100 to AEC-Q200. Beyond these standards, using AS9100D-certified PCBs is recommended. All these standards ensure the highest quality in manufacturing and the final product's PCB quality.
Creating automotive PCBs according to standards is a complex process. Therefore, it is essential to involve specialists with knowledge and experience in this field from the design stage. Compliance with standards from the initial design phase, implementing quality management systems, and carefully selecting materials are essential steps in creating PCBs suitable for the automotive industry.
Specific Requirements and Standards for Automotive PCBs
What Standards Govern Automotive PCBs?
Beyond these three standards, it is worth considering the use of AS9100D-certified PCBs.
Environmental Factors in the Automotive Environment
Electromagnetic Compatibility (EMC) and Interference (EMI) in PCBs
Material Selection and Compliance for Automotive PCBs
Environmental Regulations Are Important for Safety and Sustainability
Strict Testing Protocols for Automotive PCBs
Additional Tested Properties for Printed Circuit Boards:
The Need for Long-Term Availability and Traceability of PCBs
