集成式FPC-PCB在动力电池管理系统中的应用

Application of Integrated FPC-PCB in Battery Management System

当前动力电池管理系统在设计采样回路时多采用线束和接插件连接电芯和控制器。随着电池包电芯数量的增加,采用线束和接插件的连接方式,首先布线很难做到规整划一,走线需要压缩有限的电池包空间,装配对人工依赖很大,不利于自动化、集成化生产;其次接插件很难做密封设计,且占用较大的高度空间,不利于电池包空间优化。随着电池包内模组数量的增加,接插件数量和线束长度也随之增加,成本压力越来越大,不利于低成本发展方向。针对以上问题,提出一种基于FPC和PCB的软硬板集成连接方案,将线束变更为FPC,取消接插件,采用焊接形式做FPC-PCB的一体化集成,优化接口设计,有效降低了高度空间和成本,适应自动化、集成化发展趋势。本文首先设计FPC,其次对FPC-PCB连接接口进行设计优化,对焊接工艺进行对比选型,最后设计试验验证连接性能。验证结果表明该集成式连接方案满足设计要求,可应用于电池管理系统中的低压采样回路。

Currently,in the design of sampling circuit of battery management system(BMS),wire harness and connector are used to connect the cells and controller.Firstly,With cell quantities increase in battery pack,it is difficult to achieve uniform for wire harness connection.Wiring needs to compress the limited space of battery pack.Assembly depends heavily on manual work,which is not conducive to automation and integrated production.Secondly,connector is difficult to do sealing design and occupies a larger height space,which is not conducive to the optimization of battery pack.With the increase of the number of modules in the battery pack,the number of connectors and the length of wire harness also increase,leading to the cost increase,which is not conducive to the direction of low-cost development.In order to solve the above issues,one FPC and PCB integrated connection solution is proposed.The wiring harness is changed to FPC,the connector is cancelled,and the integrated connection of FPC-PCB is made by welding.The interface design is optimized,which effectively reduces the height space and cost,and adapts to the development trend of automation and integration.Firstly,the FPC is designed,secondly,the FPC-PCB interface is designed and optimized,and the welding process is compared and selected.Finally,the connection performance is validated.The validation results show that the integrated connection solution meets the design requirements and can be applied to sampling circuit in battery management system.