How does inductor selection impact long-term battery pack reliability?
BMS power circuits operate continuously throughout the vehicle’s life, often for thousands of hours under elevated temperature. Excessive inductor losses increase local temperature, which accelerates aging of electrolytic capacitors, MOSFETs, and PCB materials. In extreme cases, thermal cycling combined with vibration can cause solder fatigue or mechanical cracking. Low-loss, thermally stable inductors help minimize internal temperature rise, reducing stress on surrounding components and extending the overall lifetime of the battery pack electronics.