Hello everyone,
We are KA-RaceIng, the Formula Student Team from Karlsruhe Institute of Technology. Each year, we design and build a new electric, autonomous race car to compete in international Formula Student competitions against teams from universities around the world.
For the 24/25 Season, Aisler gracefully provided us with numerous PCB manufacturings. In return, we offered to showcase some of these projects.
Low Voltage Battery Stack PCB
Our Racecar has both a High-Voltage and a Low-Voltage battery. The Low-Voltage battery works by first glueing the Li-Ion Cells together and then attaching them to the so-called Stack-PCB. The Stack PCB has slits in it where the Celltabs (Copper Strips that are basically the terminals of the cell) are threaded through. On top of the the Stack-PCB, the busbars are riveted onto large Vias. These are made of aluminium and also have slits in them. When the cells are threaded through there, the busbars are bent together so that they pinch the celltabs. After that, they are laser-welded together. You can see these welds in the picture. Other than that, there are some SMD Fuses provided by Littlefuse on there, as well as temperature sensors (NTCs) and a Connector which connects each Cell to our Battery Management System to allow for both monitoring and Balancing.
Thanks again to Aisler for gracefully providing us with the manufacturing budget! I hope this small post gave you an insight into our electronics. For more information visit our website or socials.