Simulation Apps Uncover the Hidden Cause of Electronics Failure in EVs

High-voltage electronics are the lifeblood of electric vehicles, wind farms, and data centers. But with higher power comes greater vulnerability to a silent killer: humidity. Moisture that seeps into enclosures can condense on circuit boards, leading to corrosion, leak currents, and even catastrophic dendrite shorting. Despite this, nearly half of all electronics failures are attributed to an unknown root cause, because the telltale signs often disappear without a trace.

Researchers at the Technical University of Denmark’s CELCORR center are tackling this problem head-on. They’ve built multiphysics simulation models that replicate condensation on PCB surfaces, allowing engineers to visualize how design choices—like electrode spacing or coating thickness—affect corrosion risk. By varying parameters in a virtual environment, teams can identify weak points before a physical prototype ever exists.

The real innovation, however, is in accessibility. CELCORR has developed intuitive simulation apps that hide the complex math behind a simple interface. Engineers at partner companies can now tweak inputs and instantly see how changes influence leak current, turning corrosion analysis into a plug-and-play design tool. This democratization of advanced simulation is helping the industry move from reactive troubleshooting to proactive, humidity-robust engineering.

Looking ahead, CELCORR is expanding its focus to high-power, high-voltage systems, where the stakes are even higher. With a recent grant from the Grundfos Foundation, they’re establishing a new center dedicated to climate-robust electronics design. The goal is clear: arm engineers with the knowledge to build electronics that can withstand the world’s harshest conditions, ensuring reliability from the grid to the open road.