IPC International Community magazine an association member publication
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90 I-CONNECT007 MAGAZINE I FEBRUARY 2026 ADAS: Safety-Critical Electronics ADAS technologies such as automatic emergency braking, adaptive cruise control, lane-keeping assistance, blind-spot detection, and driver moni- toring are among the most safety-critical electronic systems in an EV. These features rely on a fusion of sensors, including cameras, radar, ultrasonic sensors, and increasingly LiDAR, all coordinated by high-performance processors. 2 Reliability challenges arise because ADAS elec- tronics must operate accurately under extreme temperature swings, vibration, precipitation, 3 road debris, and electromagnetic interference (EMI). Field investigations have shown that sensor degra- dation, 4 misalignment, or contamination 5 can lead to false alerts or system disablement, 6 undermining both safety and driver confidence. In some cases, vehicles revert to reduced-function modes when sensor data becomes unreliable, impacting usabil- ity even when no hardware failure has occurred. The shift toward centralized or zonal electronic architectures further amplifies reliability risk. Multi- ple ADAS functions may now reside on a single domain controller, improving efficiency and reduc- ing wiring complexity but increasing the conse- quence of single-point failures. This makes fault isolation, redundancy, and graceful degradation essential design-for-reliability (DfR) considerations. 7 Robust validation of ADAS electronics increas- ingly requires combined-environment testing, including thermal cycling under bias, vibration with live sensor operation, and EMI susceptibility test- ing beyond minimum regulatory requirements. 8 Over-the-air (OTA)-enabled field monitoring is also becoming a key tool for detecting early-life reliabil- ity issues before they escalate into safety recalls. 9 Connectivity: Enabling Features While Introducing New Failure Modes Connectivity has become a defining attribute of EVs. Telematics systems, vehicle-to-cloud commu- nication, vehicle-to-everything (V2X) interfaces, and OTA software updates enable continuous improve- ment, remote diagnostics, and feature upgrades. However, they also introduce new reliability and cybersecurity challenges. 10 Connectivity hardware including antennas, gateways, telematics control units, and network switches is often distributed across the vehicle and exposed to harsh environ- ments. Failures in these modules can disrupt func- tions ranging from navigation and infotainment to safety recalls and compliance updates. 11 OTA updates exemplify the dual nature of connec- tivity. They allow manufacturers to address issues without physical service visits, but insufficient vali- dation can introduce unintended consequences. Documented cases show that OTA updates intended to fix existing issues can in fact intro- duce new problems. For example, an OTA update to Jeep Wrangler 4xe vehicles disrupted vehicle module communication and caused drive system malfunctions, leading to a recall and rollback of the software release, underscoring the need for rigor- ous regression testing and rollback strategies when deploying OTA updates in connected vehicles. 12 As EVs transition toward software-defined vehi- cle (SDV) architectures, distinguishing between soft- ware-induced faults and underlying hardware weak- nesses becomes increasingly complex. 13 Reliable connectivity therefore depends not only on robust electronics design, but also on disciplined software lifecycle management. Driver Interfaces: Reliability as a Measure of Quality Human-machine interfaces (HMIs) including touchscreens, digital instrument clusters, head- up displays, voice controls, and haptic feedback systems, are now central to the EV driving experi- ence. Unlike many powertrain components, inter- face failures are immediately visible to drivers and strongly influence perceptions of vehicle qual- ity. 14 EV HMIs integrate high-resolution displays, advanced graphics processors, and complex soft- ware stacks. These systems must remain respon- sive across a wide range of temperatures, light- ing conditions, and usage patterns. Field reports have linked display delamination, touchscreen unresponsiveness, and intermittent resets to ther- mal stress, material incompatibilities, or inadequate assembly robustness. 15 Importantly, HMIs are not merely convenience features. They serve as the primary channel for safety alerts, ADAS warnings, and system status information. Delayed or ambig- uous alerts can impair driver response and erode trust in automated assistance systems. Reliability expectations rise as manufacturers consolidate multiple vehicle functions like climate

