Hello PCB Developers,
As part of the Formula Student Team Raceyard E, we have engineered a redesigned busbar and monitoring architecture for our 600V high-voltage accumulator. At the core of this assembly is the accumulator carrier board (AMB), which combines mechanical integration with precision sensing. The PCB serves both as a structural mount for our copper busbars and temperature sensors, as well as the electrical interface for the battery management system (BMS).
Each AMB incorporates 9 fused voltage taps and 10 NTC thermistors, reliably routing the acquired cell data to an external BMS slave. Structurally, the high-current copper busbars are directly bolted onto the PCB, with the individual battery cell tabs ultrasonically welded onto the busbars.
To withstand the mechanical loads of assembly, the layout strictly avoids routing any copper traces directly beneath the weld zones, preventing internal layer damage from ultrasonic energy and clamping pressure. Additionally, dedicated threaded stud mounts are distributed along the assembly to anchor the PCB inside the battery container, effectively preventing mechanical deflection across the board’s 430 mm overall length.
We have been very satisfied with the quality of the PCB and are pleased to have found a reliable partner for large PCBs.