Recalls by EV Original Equipment Manufacturers (OEMs) have often been linked to particle-induced electrical breakdowns in the high-voltage range. Additionally, the ingress of moisture into OCB/DC/DC units, coupled with contamination, has heightened the risk of failures, leading to safety recalls. The absence of standards, such as IEC 60664, covering electrochemical migration (ECM) presents a unique challenge in ensuring proper insulation in the high-voltage (HV) range, rendering the design landscape complex for engineers.

In addition to well-known failure mechanisms under humidity, such as ECM and creep corrosion, emerging failures like AMP stemming from the aging process of insulation materials, present further challenges. These failures may manifest much later and result in short circuits, alongside the risk posed by particles leading to arc discharges and thermal incidents. Addressing these risks is a crucial aspect of design Failure Mode and Effects Analysis (FMEA).

The integration of accelerated stress tests reflects a novel analytical approach to insulation coordination. By addressing critical failure causes identified through HV tests, production costs for EV units can be significantly reduced. These failures are often complex in nature, therefore previous approaches focusing solely on pollution degree and particle geometry are inadequate.

Embracing this philosophy eliminates the need for traditional expenses such as clean rooms, extensive monitoring, and stringent cleanliness rules throughout the production facility. Instead, a process lock at validation is achieved, and with smart solutions, such as dedicated cleaning processes strategically positioned along the production line, paves the way for streamlined and efficient production.