3 Busbar & Electrical Module Design

Dr. Gael Chouchelamane

Verified Author

Info Current and Verified

Updated 06/2025

Short Description

The Busbar and Electrical Design stage focuses on designing all electrical pathways and components within the battery module. It ensures safe and efficient current flow between cells, accurate monitoring of cell status, and reliable connection to the external system or battery pack. Key aspects include designing cell-to-cell interconnects (busbars), module connectors for power and signals, integrating the Cell Supervising Circuit (CSC), managing low-voltage (LV) harnesses, and ensuring electrical safety through appropriate creepage and clearance distances.

Key Activities

3.1 Cell-to-Cell Interconnects

Busbar design involves selecting conductive materials (copper, aluminum, nickel) based on performance and joinability, sizing for current loads, and shaping for fit and efficiency. It includes secure attachment methods, proper creepage/clearance, and strain relief for thermal and mechanical stresses.

3.2 Power & Signal Connectors

Select HV power connectors for max current/voltage, and LV signal connectors for CSC/BMS comms (e.g., CAN, LIN). Ensure proper IP rating, current capacity, material compatibility, locking, mating cycles, and secure cable/harness integration.

3.3 CSC Integration

Define CSC requirements: voltage and temperature sensing points, balancing current, communication (e.g., CAN), and diagnostics. Choose between off-the-shelf or custom CSC. Design placement, mounting, and connectors to interface with cells, busbars, and external signal connectors.

3.4 Low-Voltage Harness

Design low-voltage wiring for CSC power, comms, and sensors—specifying wire gauge, insulation, and connectors. Ensure protection from vibration, heat, and chafing. Optimize for easy assembly and minimal EMI to ensure safe, reliable operation within the module.

3.5 Electrical Simulation

Simulate current distribution, voltage drop, and thermal effects (Joule heating) in busbars and interconnects. Analyze short circuit response and fuse behavior. Model EMI/EMC to ensure electrical performance and compliance with safety and interference standards.

Core Technologies & Materials

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