IEEE Transactions on Components, Packaging and Manufacturing Technology, PP(99):1-11 · April 2018. DOI: 10.1109/TCPMT.2018.2815633

Hybrid Approach to Conduct Failure Prognostics of Automotive Electronic Control Unit Using Stress Sensor as In Situ Load Counter

Bulong Wu1, Alexandru Prisacaru2, Alicja Palczynska2, Przemyslaw Gromala2, Bongtae Han3, Dae-Suk Kim4
2Department of Mechanical Engineering, University of Maryland, College Park, Maryland 20740, USA
2Robert Bosch GmbH, Division of Automotive Electronics, Stuttgart, Germany
3CALCE, Center for Advanced Life Cycle Engineering, Department of Mechanical Engineering, University of Maryland, College Park, Maryland 20740, USA
4Qualcomm, San Diego, California, USA


A model/sensor hybrid approach is implemented to conduct failure prognostics of an automotive electronic control unit (ECU). A 3-D finite-element model simulating a complex ECU is built, and its predictability is calibrated and verified by an optical displacement measurement technique called moiré interferometry. On the sensor front, a silicon-based piezoresistive stress sensor is embedded into the ECU to provide in situ stress measurements during operations. A stress metric is defined using the stress values of 12 cells in each sensor, and it is converted to in situ loading histories using the calibrated finiteelement model. The modeling and verification steps that lead to the predictive finite-element model are described. The proposed hybrid approach is implemented using the data obtained from a molded ECU subjected to thermal cycling conditions, and the forces at an interface between an aluminum wire bond and metal pad are investigated.

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