A low voltage / signal harness is required to connect the voltage measurement points, temperature sensors and other sensors to the measurement channels. This can be done directly with a central control board or a number of lower level measurement boards that are then daisy chained to allow them to communicate with the central processor.
Either way the harness requirements should not be underestimated.
Flexible Printed Circuits (FPCs) are the hidden nervous system of high-voltage batteries, yet their reliability is often overlooked.
For long-term reliability, FPC design deserves as much focus as chemistry and cooling.
- Signal Pathway: Every cell voltage and thermistor channel depends on the FPC.
- Space & Weight Efficiency: Slim, lightweight alternatives to bulky wiring harnesses.
- High-Voltage Environment: Subjected to constant electrical, thermal, and vibration stress.
- Single Point of Failure: A single crack or loose connector can disable a full module.
See also: Electrical System of Battery