In recent years, the automobile industry has undergone a large-scale transformation from fuel vehicles to electric vehicles such as new energy vehicles. New energy vehicle PCB is a unique circuit board specially designed for these electric vehicles. Since electric cars require more PCBs than conventional cars, the shift from conventional cars to electric cars has increased the demand for PCBs in the automotive world.
New energy vehicles have unique components that make them different from traditional vehicles. Here are their components:
New energy vehicles have three PCB-based main power control systems.
The VCU of new energy vehicles is mainly composed of control circuits and algorithm software. It is built on the PCB of new energy vehicles and regulates its operation. Its function is to supervise the vehicle and make decisions on the power control system. The PCB used to control the VCU is approximately 0.03 square meters.
Similar to VCU, MCU is also composed of control circuit and algorithm software. The MCU regulates the vehicle’s electric motor according to the instructions of the VCU, so that the electric motor can send alternating current to the vehicle. The PCB of the MCU is approximately 0.15 square meters.
BMS is an important part of the new energy vehicle battery system. The main function of BMS is to manage and protect the battery pack. BMS does this by performing multiple tasks. It collects and calculates voltage, current and SOC data to control battery discharge and charging. The BMU checks the voltage, current and balance control of the battery cells.
The hardware of BMS consists of BCU and BMU. The BCU component of the battery management system controls relays, estimates SOC and provides electrical protection. The BMU monitors voltage data, and battery current, and ensures control balance in the vehicle’s power control system. All these features of the BMS help prevent battery damage.
Due to the complexity of BMS, it requires a multilayer PCB for stability and proper operation. It also requires several PCBs. The main control unit requires approximately 0.24 square meters of PCB, and a single management system requires 2 to 3 square meters.
New energy vehicle PCBs have a variety of applications in the automotive industry. Here are some of their popular applications:
New energy vehicle PCBs have some unique features that make them different from other PCBs. Here are some of the features:
A major feature of new energy vehicle PCBs is high-temperature resistance. These PCBs have a lower density, which helps them dissipate heat. They have unique properties that make them suitable for high temperatures.
New energy vehicle PCBs are reliable and have a long service life because they are made of high-quality, high-strength materials. They are suitable for the harsh working conditions of automobiles and will not cause any damage even in different locations and under different environmental conditions.
Vehicles attract dirt to themselves as they drive. To help protect these vehicles from dirt and its negative effects such as short circuits and failures, these PCBs are designed to be dust-proof. New energy vehicle manufacturers use various laminate materials on these PCBs to protect them from dust contamination.
In new energy vehicles (NEVs), several types of printed circuit boards (PCBs) are commonly used, each serving a critical role in the vehicle’s performance and functionality.
are essential for overseeing the health and safety of the battery pack. These boards monitor battery cells, balance their charge, and protect against overcharging or overheating, ensuring the longevity and efficiency of the battery system.
manage the operation of electric motors by controlling power delivery and ensuring smooth, responsive performance. They handle complex tasks such as speed regulation and torque control, crucial for the vehicle’s overall drivability.
facilitate the connection between the vehicle and charging stations. They manage power flow, communication protocols, and safety features, ensuring efficient and reliable charging across different types of charging infrastructure.
are used in various systems such as infotainment, navigation, and driver assistance technologies. They enable complex data processing and communication between different vehicle systems, enhancing the overall driving experience.
Designing and prototyping PCBs for new energy vehicles (NEVs) involves a comprehensive process to ensure that each board meets the exacting standards required for optimal performance and reliability. Here’s a detailed look at each stage of this critical development process:
The initial phase focuses on establishing the precise specifications for the PCB based on the unique needs of the NEV system. This includes setting parameters like board thickness, the number of layers, and the choice of materials—ranging from standard FR-4 to specialized high-frequency materials for radio frequency applications. Key aspects such as impedance requirements, surface finishes (such as HASL or ENIG), hole sizes, and spacing are also determined. These specifications are vital for ensuring the PCB’s electrical performance and physical compatibility within the NEV’s systems.
With specifications in place, the design phase begins using advanced PCB design software. This involves creating the board layout, including the strategic placement of components, routing of electrical traces, and setting up power and ground planes. Comprehensive checks are performed to identify and correct errors, inconsistencies, or violations in the design, such as improper connections or inadequate clearances. Design Rule Checks (DRC) and Electrical Rule Checks (ERC) are essential to validate the design’s integrity and functionality.
Once the design is finalized and validated, Gerber files are generated. These files are the industry-standard format that provides a detailed description of the PCB design, including copper layers, solder masks, silkscreen layers, drill holes, and other necessary details. These files serve as the blueprint for PCB manufacturers, guiding them in accurately producing the boards according to the design specifications.
For multilayer PCBs, a stack-up document is created to outline the layer arrangement and sequence, which includes signal layers, power planes, and ground planes. It also specifies the dielectric materials used between the layers and their thicknesses. This documentation is crucial for ensuring signal integrity, controlling impedance, and maintaining mechanical stability throughout the PCB’s operation.
With design and stack-up documents in hand, the prototype manufacturing process begins. This stage typically involves using a subtractive manufacturing process where copper is etched away from the substrate based on the design. Techniques such as laser drilling are used to create precise vias and microvias. Additionally, surface finishes like HASL, OSP, or ENIG are applied to protect the copper traces and ensure reliable soldering.
Following the manufacturing of prototype PCBs, components are assembled onto the boards using surface mount technology (SMT) or through-hole technology (THT). These assembled prototypes undergo rigorous testing to validate their functionality and compliance with design specifications. Testing includes electrical assessments, functional evaluations, and environmental simulations to ensure that the PCB performs reliably under various operating conditions.
Based on the results from testing, the design may go through an iterative refinement process. This involves revisiting and making necessary adjustments or optimizations to address any issues or improve performance. This iterative approach helps in fine-tuning the design to meet all performance and reliability criteria before proceeding to mass production.
By adhering to these detailed steps, the PCB design and prototyping process ensures that new energy vehicle PCBs are robust, reliable, and perfectly suited to the demanding requirements of NEV systems. The iterative nature of the process allows for continuous enhancement and refinement, ensuring that the final product excels in performance and integration.
IBE is committed to providing innovative and reliable automotive electronics manufacturing solutions to help automakers develop cutting-edge vehicles that define the future of mobility. Our engineers conceive and design electronic systems suitable for specific models, implement strict quality control processes, and conduct comprehensive testing to ensure that electronic systems meet safety and performance standards.
New energy vehicles have three PCB-based main power control systems. including:
