As technology advances, vehicles are gradually transitioning from fuel to electric power. This change necessitates adding electrical systems to vehicles to make them functional. However, such changes present new challenges to ensure the reliability of electric vehicles (EVs) on the road and over long distances.
In this article, we’ll explore the challenges high-frequency printed circuit boards (PCBs) face when used in EV applications and the solutions to resolve these issues.
The role of PCBs
PCBs play a vital role in EVs because they serve as the backbone for various electronic components and modules, including:
- Powering up the powertrain – the motor, controller, and battery of an electric vehicle are reliant on complex high-frequency PCBs whose durability and reliability directly impact the car’s longevity and efficacy.
- Overseeing the battery management systems – a dedicated high-frequency PCB powers the battery pack of an electric vehicle. The PCB is responsible for monitoring the battery’s health, and state of charge and can control the temperature.
- Ensuring reliable infotainment and internet connectivity – EVs are more than a means of transportation; they’re also mobile tech hubs. A high-density interconnect PCB is integrated into an EV to facilitate high-speed data transfer and enable entertainment modules inside the vehicle.
- Managing the recharging infrastructure – high-frequency PCBs manage a vehicle’s charging infrastructure. They’re integral to the onboard chargers that take electricity from the power grid to recharge the car. The reliability and functionality of the onboard chargers are very dependent on the PCB’s quality.
Every challenge has a solution
Integrating high-frequency PCBs in EVs presents challenges that may include the following:
An engineer analyzing an electric vehicle’s electrical configuration.
1. Mechanical stress. Road surfaces are rarely consistent. During any trip, drivers may experience the odd bump or different vibrations due to uneven pavement. This may present an issue for EVs, as repeated mechanical stress and vibration can damage key components. The ideal solution is to strengthen the PCBs using durable but suitable materials and vibration fatigue analysis.
Vibration fatigue analysis is the study of movements and vibrations and, used in this case, how they can affect the PCB. This analysis includes identifying key points where a PCB can fail or crack, allowing designers and engineers to apply modifications or materials that ensure this component is more durable and shock-proof.
2. Heat dissipation and management. EVs generate a lot of heat, which can reduce their reliability and lifespan. So, they require a sufficient thermal management system to prevent overheating. To attain optimal temperatures, PCB designers must add thermal management mechanisms, such as thermal vias, heat sinks, and heat pipes. By adding these components, an EV’s high-frequency PCB can maintain safe temperature levels, prolonging the operational lifespan and reliability of the vehicle.
3. Exposure to electromagnetic waves. One challenge that high-frequency PCBs face in EV applications is electromagnetic interference caused by either high-powered or sensitive electronic parts being close to each other. One consequence is that electromagnetic waves can disrupt an EV’s operations, which can be detrimental to the safety of the passengers.
The solution to this issue is to add sufficient shielding, ground plane separation, and filtering to a PCB to weaken the effects of electromagnetic waves that can interfere with the car’s functionality.
4. Spacing concerns. PCB designers are often challenged to find adequate space to safely fit these components in EVs. Fortunately, there’s a simple solution: employ miniaturization techniques on the PCB design and add multiple functions on the circuit boards.
Miniaturization and multi-functionalization of the PCBs allow them to become more compact and lightweight, making it easier for them to fit into an EV’s electrical system.
A glimpse of an electric vehicle’s engine.
5. Handling powerful electric currents. High-frequency PCBs must properly handle strong electric currents during vehicle operation, which carry a lot of heat that can build up inside the electrical systems. If left unchecked, the accumulated heat from the flowing currents can negatively alter EV performance and lifespan.
To address this concern, heavy copper and other advanced materials that can withstand strong currents are used on the printed circuit board — making it better at safely carrying electrical currents. Aside from that, designers must apply optimal layouts and heat dissipation mechanisms to ensure flowing electric currents are manageable.
Summary
High-frequency PCBs face significant challenges when used in EV applications. It’s imperative to address issues, including thermal management, electromagnetic interference, space limitations, and electric currents.
Fortunately, reliable solutions are available that, if applied correctly, will mitigate or avert potential hazards, such as overheating or reduced operational lifespan of electric vehicles.
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