PCB With Integrated Busbar for High Voltage Battery in a Formula Student car

Printed circuit boards (PCBs) enable robust and precise electrical connections in electronic devices. In the KTH Formula Student car, several PCBs are used, including those in the battery management system (BMS). The present measurement PCB utilizes busbars between the battery cells, mounted below the board. This design introduces several problems in terms of space, accessibility, and overall structure. This thesis revolves around the integration of busbars directly into the measurement PCB for high voltage battery applications, with the aim to improve the overall functionality and reduce space. Among several approaches investigated, an implementation utilizing internal PCB traces across multiple layers was selected. This solution distributes the current through the PCB stack with copper traces. Encouraging results are shown in both simulations and experimental testing in terms of current handling and thermal conductivity.