Hey folks,
we are the Os.Car Racing Team, the Formula Student team based at the University of Applied Sciences Vienna. Our goal is to manufacture a prototype ICE and hybrid-powered vehicle every year to compete in various Formula Student competitions around the world.
In this article, we are glad to present our new Power Distribution PCB, which will be used in the 2026 events.
What is the purpose of the Power Distribution PCB?
The goal of the new PCB is to make efficient use of the limited space typically found in ICE-powered Formula Student race cars. The ICE unit and its core components take up around 70% of the available space at the rear of the vehicle.Additionally, we introduced the first hybrid car in the team’s history, the CR-124h, during the 2025 Formula Student season. This added further space constraints within the frame envelope.
Instead of relying on multiple in-line fuse holders and a separate relay box, we decided to integrate them into a single unit, separating low-level and high-level loads.
One of the biggest achievements is the seamless CAN bus integration, which allows us to control the loads using the built-in automotive relays. By integrating the PCB with our existing systems, we reduce unnecessary cable routing to the unit itself and free up outputs on other control units.
Design choices
- We decided on a 2 oz copper design for the outer layers, made possible by Aisler’s manufacturing capabilities, to achieve higher current flow to the components through the 12V battery or alternator while the car is running.
- To protect the IC controlling the relays, we use a 4-layer PCB design with a GND return plane placed close to the logic components. This helps reduce EMI interference.
We would like to thank Aisler for their quick and easy PCB manufacturing service. Without their support, our R&D work could not be turned into real, high-performing components operating under the best possible conditions.
Cheers, and see you next time!