The Global Electronics Association has released a new white paper examining reliability challenges in battery management systems as electric vehicle (EV) architectures move toward higher voltages, continuous operation and longer service lives.
The paper argues that traditional qualification methods may not fully capture failures that develop gradually under real-world operating conditions. These can include moisture intrusion, insulation degradation, sensor drift and connector failures that emerge after prolonged exposure rather than during short-duration component testing.
Modern BMS electronics are increasingly expected to remain active for long periods while operating in 800 to 1,200 V vehicle architectures. At the same time, the electronics may be exposed to heat, humidity, contamination, and vibration over the life of the vehicle.
According to the association, those conditions create a need to evaluate reliability at the complete-system level rather than relying solely on qualification of individual components.
The paper recommends testing complete BMS assemblies under combined environmental and electrical stresses that better reflect how the electronics will operate in a vehicle. It also calls for validation methods that account for continuous electrical bias and longer-duration operation.
A central concern is the gap between accelerated qualification testing and the gradual degradation mechanisms that can appear over years of service. Connecting validation more closely to expected vehicle life could help manufacturers identify failure modes that would otherwise remain hidden until after deployment.
The white paper, titled Why “Always-On” BMS Electronics Demand a New Reliability Approach, focuses on how battery-management electronics should be tested as EV battery systems become more powerful, more highly integrated, and increasingly dependent on reliable high-voltage control throughout the vehicle’s service life.
Download the white paper here.
Filed Under: Batteries, BMS, Technology News