Difficulties and Challenges in PCB Design for Electric Vehicles

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With the increasing awareness of environmental protection and the impact of fluctuating oil prices, more and more consumers are considering purchasing new energy vehicles as a means of transportation. In addition, the brand image and service quality of new energy vehicles are also improving, attracting more consumers. The market share of electric vehicles continues to grow, and more and more automakers are launching electric vehicles. Meanwhile, with the further development of battery technology and the improvement of infrastructure, the future development of electric vehicles is promising.

Electric vehicles have a very wide market, but the design requirements are getting higher and higher, which includes the difficulties of PCB design for electric vehicles. This article will give you a detailed introduction to the difficulties and challenges of PCB design for electric vehicles.

Difficulties in electric vehicle PCB design mainly include the following aspects:

1. High reliability PCBs and components installed on the board must meet high reliability standards, because it is related to the safety of operation and life. When the car works in a harsh environment, it will encounter vibration, shock and other problems, so the circuit must have a certain corrosion resistance and resistance to harsh environments.

2. High security requirements. The car must ensure the safety of the entire vehicle system, or even zero defects. In electric vehicles, the importance of information security is becoming more and more prominent, so security measures such as data encryption are required.

3.The PCB needs of electric vehicles mainly come from powertrain-related equipment, on-board equipment, battery management system (BMS), voltage conversion systems (DC-DC, inverters, etc.), and other high-voltage and low-voltage equipment, which require highly durable, reliable and rugged PCB applications.

4.PCB design needs to adapt to the evolving new energy drive system, so innovative PCB applications are needed to meet these needs.

PCB Design Challenges for EVs

PCBs play a vital role in managing complex EV electronic systems. Designing PCBs for electric vehicles comes with unique challenges that engineers and designers must overcome to ensure optimal performance, safety, and reliability.


Size and Space Constraints
To maximize limited space, PCB designers must optimize components and routing paths. The challenge intensifies as the demand for additional functionalities, such as advanced driver assistance systems, increases. Maintaining structural integrity while accommodating sensors, communication modules, and safety features is challenging.

Thermal Management
In electric vehicles, thermal management is crucial for reliable and safe operation. Designers must carefully plan and implement cooling mechanisms to prevent overheating and ensure long-term reliability. A combination of high-power components and limited space necessitates using advanced thermal management techniques like heat sinks, heat pipes, and thermal vias to dissipate heat efficiently.

Vibration and Mechanical Stress
Due to uneven surfaces and vehicle acceleration, electric vehicles are subject to various mechanical stresses and vibrations. PCB designers must ensure that their boards are durable and reliable in these conditions. These challenges can be mitigated by strengthening the PCBs, selecting suitable materials, and using techniques like shock and vibration damping.

Electromagnetic Interference
Due to high-power components and sensitive electronic systems operating close together, electromagnetic interference (EMI) is a big concern in electric vehicle PCB design. To minimize EMI and maintain signal integrity, designers must use shielding techniques, ground plane separation, and filtering. Compliance with electromagnetic compatibility standards and regulations is crucial to prevent interference with other vehicle systems and external devices.

Safety and Reliability
Electric vehicles have to be safe and reliable. PCB designers need to follow strict safety standards. It’s important to ensure the appropriate isolation of high-voltage circuits, implement redundant systems for critical functions, and validate PCB designs for reliability and fault tolerance.

Electronic systems for electric vehicles pose a lot of challenges for PCB designers. Managing power electronics, optimizing space, and addressing thermal management and EMI issues are all part of the design process. PCB designers can help make electric vehicles safer, more reliable, and more efficient by addressing these challenges head-on and leveraging innovative design techniques.

PCB designers working on EV projects can use Cadence tools to help with challenges for electric vehicle design. Cadence tools include PCB Design and Analysis Software and OrCAD PCB Designer.