Full Process of New Energy Vehicle Electronic PCBA Circuit Control Board Manufacturing
With the rapid development of the new energy vehicle (NEV) industry, electronic PCBA circuit control board manufacturing has become a critical component in supporting intelligent, safe, and efficient vehicle operation. The stability and precision of the electronic control system directly affect overall vehicle performance, lifespan, and driving safety.
This article provides a comprehensive analysis of the core systems, manufacturing processes, quality inspection standards, and reliability control of NEV PCBA boards.
I. Core Components of NEV Electronic PCBA Circuit Boards
Key PCBA control boards in new energy vehicles include:
Vehicle Control Unit (VCU)
Motor Control Unit (MCU)
Battery Management System (BMS)
Charging System Control Boards
Advanced Driver Assistance System (ADAS) Boards
Take the BMS board as an example—it requires precise monitoring and adjustment of parameters such as battery voltage, current, and temperature. This demands extremely high manufacturing accuracy, as even minor errors can lead to safety risks and performance degradation.
II. Key Manufacturing Technologies in NEV PCBA Processing
1. Precision Surface Mount Technology (SMT)
NEV electronic boards contain a large number of miniature components that require extremely precise placement.
For instance, ADAS boards use sensor chips with extremely fine pitch. Advanced SMT equipment with high-resolution vision systems ensures micron-level placement, maintaining signal integrity and performance.
2. Multi-layer PCB Manufacturing
To achieve high integration and compact size, NEV control boards often use multi-layer PCB designs (typically 6–12 layers).
For example, a VCU control board may involve the following steps:
Inner layer circuit imaging
Lamination, drilling, and plating
Precise layer alignment and inter-layer connectivity
Multi-layer designs help reduce signal interference and enhance the efficiency of system control.
3. Optimized Soldering Techniques
Reflow soldering: For most SMT components
Wave soldering: For high-power through-hole components
Selective soldering: For precise soldering of sensitive or critical components
For example, in the MCU board, power modules require excellent heat dissipation and strong mechanical bonding, which is achieved through hybrid soldering techniques.
III. Strict Quality Assurance System
1. Raw Material Inspection
All base materials and components are rigorously inspected, including:
Checking for oxidation or deformation of chip leads
Ensuring electrical parameters meet design specs
Confirming materials meet temperature and EMI resistance requirements
Strict control at the source ensures PCBA reliability.
2. In-Line Process Monitoring
AOI (Automated Optical Inspection): Detects missing, misaligned, or lifted components
Flying Probe Testing: Verifies circuit continuity and shorts
X-ray Inspection: Detects hidden solder defects like voids or cold joints
Each step is closely monitored to maintain high process standards.
3. Functional Testing
Before delivery, every PCBA board undergoes comprehensive functional testing under simulated vehicle conditions:
Voltage/current stability
Communication interface integrity (e.g., CAN, LIN)
Overvoltage/short circuit protection
Self-diagnostic capabilities
For instance, PCBA boards for EV charging systems are tested for control precision, communication protocol compatibility, and protective functionality.
IV. Material and Environmental Adaptability Requirements
NEV PCBA boards must operate reliably under harsh automotive environments, including:
Wide temperature ranges (-40°C to +125°C)
Strong electromagnetic interference (EMI)
High humidity and vibration
Thus, PCBA manufacturing must use:
High-TG base material (e.g., FR4 TG170+)
Anti-oxidation finishes (e.g., ENIG, OSP)
Vibration-resistant soldering techniques
Only with these measures can long-term operational stability be ensured.
PCBA Manufacturing: The "Smart Brain" Behind New Energy Vehicles
The manufacturing of NEV electronic PCBA control boards is not just about assembly—it's a combination of precision engineering, quality assurance, and system integration. It plays a vital role in defining the performance, safety, and user experience of electric vehicles.
If you're looking for a professional NEV PCBA manufacturing partner, feel free to contact us for free samples and customized solutions tailored to your needs.