CCS (Cell Connection System) is a core component of the Battery Management System (BMS). By integrating signal acquisition elements, plastic structural parts, and copper-aluminum busbars, it can sample the voltage and temperature of the cells and complete high-voltage series and parallel connections, thereby improving the battery's space utilization and driving range.

Key Functions

1. Connects single cells according to design requirements to form the desired system voltage and capacity. Supports system voltages up to 1,000 V DC and current up to 500 A per busbar, enabling flexible series and parallel configurations for large-scale battery modules.

2. Monitors each cell’s voltage and temperature, transmitting data to the BMS for performance optimization and safety monitoring. Voltage measurement accuracy reaches ±5 mV per cell, temperature accuracy ±1 °C, with a sampling rate of 1 Hz to 10 Hz for fast response to abnormal conditions.

3. Integrated busbar design lowers resistive losses compared to traditional wiring harnesses. Typical resistance reduction reaches 30–50 mΩ per module, improving overall system efficiency by approximately 1–2% under high current operation.

4. Compact CCS structure improves internal layout efficiency within the battery pack. Reduces wiring volume by 20–30%, contributing to higher energy density within the same installation footprint.

5. Sealed and corrosion-resistant structures improve long-term operational stability. Rated to IP65 protection level, operating temperature range from -40°C to +85°C, with vibration resistance up to 5 g RMS (10–500 Hz) and cycle durability exceeding 3,000 cycles under standard conditions.

Installation & Integration

Module Assembly: Insert busbars and signal acquisition units into pre-defined cell slots.

Electrical Connection: Securely connect busbars to cell terminals using rivets, welding, or thermal pressing.

Signal Integration: Connect the signal acquisition lines to the BMS controller.

Mechanical Securing: Attach structural components to protect the CCS under vibration and thermal expansion.

Testing & Verification: Conduct continuity, insulation, and signal integrity tests before final assembly.