CCS (Cell Contact 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.

What is a Cell Contact System (CCS)?

A Cell Contact System (CCS) is an integrated component that connects individual battery cells inside a battery pack. It combines busbars, signal acquisition wiring, and an insulating carrier into one module, replacing traditional manual wire harnesses. A well-made CCS improves battery pack safety, simplifies assembly, and reduces overall cost.

What types of CCS does Jingye manufacture?

Jingye produces CCS using three processes: injection molding, thermoforming, and direct welding. The maximum product size is up to 2000×800mm, compatible with the latest liquid-cooled battery packs. Each can be customized to match your cell layout, voltage platform, and module dimensions.

Why choose CCS over a traditional wire harness?

Compared with wire harnesses, a CCS offers better sealing against humidity and corrosion, smaller size and lighter weight, faster assembly on the production line, and lower total cost in mass production.

Can Jingye customize CCS for my battery module?

Yes. We provide full OEM/ODM services — our engineering team designs the CCS according to your cell type, module structure, and communication requirements, then validates it in our CNAS-certified testing laboratory.

How do I get a quote?

Send us your module drawings or basic requirements (cell type, cells in series/parallel, dimensions) and our team will respond with a design proposal and quotation