Thermal, Vibration, and Under-Voltage Stress Profiling during Dynamic Execution Testing

Abstract: Combining environmental chamber testing (-40°C to +125°C) with automated software functional validation to detect thermal drift and timing anomalies.

1. Combined Environmental and Electrical Stress ECU failures often occur at the intersection of extreme temperature and electrical noise. During dynamic functional testing, ECUs are housed in programmable environmental chambers cycling between -40°C and +125°C while power supplies simulate cranking voltage dips (down to 4.5V per ISO 16750-2).

2. Automated Anomaly Detection Continuous bus monitoring detected that ceramic capacitor thermal drift altered internal PLL frequencies, triggering sporadic memory parity faults. Automated stress testing identifies these hardware-software boundary issues before tooling release.