Issue link: https://iconnect007.uberflip.com/i/1544707
MAY 2026 I SMT007 MAGAZINE 55 EVs. Newer EV models are trending toward 800V battery systems to facilitate faster charging times. Higher voltages accelerate wear-out mechanisms on PCB assemblies (PCBAs), especially in combi- nation with harsh outdoor environments. Several high-voltage failure mechanisms have been described in technical papers presented at recent IPC APEX EXPO Technical Conferences. 7–9 The 2025 data further showed that hardware swaps and site refreshes, while effective at boost- ing short-term uptime, often fail to address the root causes of recurring failures. ChargerHelp found that without coordinated firmware updates, validated interoperability, and attention to en- vironmental stressors, many upgraded stations re-enter a failure cycle within months. This finding reinforces that high uptime cannot be sustained through component replacement alone; it must be engineered through robust system design and lifecycle management. As charging systems become more integrated with the grid, utilities, and energy markets, reli- ability increasingly emerges as a cyber-physical systems problem. As emphasized in the 2025 ChargerHelp report, EVSE reliability must now be evaluated across technical performance, user experience, and temporal dynamics, recog- nizing that aging hardware, firmware updates, and software interoperability collectively deter- mine long-term uptime and driver trust. Designing for Uptime: Connect-Clean-Coat In addition to temperature extremes, charging stations and their electronic assemblies are exposed to humidity, rain, snow, ice, salt spray, dust, corrosive gases, and even insects. 2 Achieving high uptime in harsh outdoor environments requires disciplined execution of proven electronics reli- ability principles. The Connect–Clean–Coat meth- odology, 10 coined by the Global Electronics Asso- ciation's e-Mobility Quality and Reliability Advisory Group (EVQR), 11 translates these principles into practical design and manufacturing framework for addressing hardware risks. • Connect: High-integrity solder joints, press-fit interfaces, busbars, and connectors capable of surviving thermal cycling, vibration, and high-current operation • Clean: Control of ionic and particulate con- tamination that can drive leakage currents, corrosion, and insulation breakdown under high voltage • Coat: Appropriate conformal coating or encapsulation strategies that protect elec- tronics from moisture, condensation, salt, and corrosive gases without compromising serviceability These are well-established practices in IPC Class 3 automotive, aerospace, and industrial electron- ics. 12–15 Their inconsistent application in EVSE manufacturing can help to explain some of the field reliability challenges observed today. Reliability, Sustainability, and Total Cost of Ownership High-uptime design is a sustainability and cost imperative. 16 Unreliable chargers drive increased service truck rolls, premature equipment replace- ment, lost revenue, and negative user percep- tion, all of which increase environmental and economic burden. Designing EVSE electronics for long service life reduces the total cost of owner- ship while supporting sustainability goals. In this context, reliability becomes the missing link between infrastructure investment and long-term environmental benefit. The Road to Reliable Power Delivery As EV adoption accelerates, charging infrastruc- ture must evolve into dependable energy systems with automotive-grade reliability expectations. The 2025 ChargerHelp findings make clear that the " Uptime is no longer a sufficient proxy for reliability. From an engineering perspective, charge-start success is emerging as the most actionable indicator of whether EVSE electronics, firmware, and communications are functioning as a system."