• Dagong ESS

Wire Harness vs PCB CCS: Traditional and Integrated Battery Signal Solutions

Wire harness CCS and PCB-based CCS are two widely used signal collection solutions in battery cell contact systems.

Wire harness CCS is the traditional approach. It uses individual wires to connect voltage and temperature sensors to the battery management system. This method has been used for many years and is known for its reliability and cost-effectiveness.

PCB-based CCS integrates signal acquisition circuits onto a printed circuit board. This approach reduces the number of separate components and enables a more compact, automated battery module design.

Both solutions are designed to perform key functions:

• Cell voltage sampling

• Temperature sensing

• Signal transmission to the BMS

• Support for cell series and parallel connections

Types of Wire Harness and PCB CCS

Wire Harness CCS

Typical structure:

• Wire harness

• Sampling terminals

• NTC temperature sensors

• Aluminum busbar

• Molded or thermoformed support structure

This configuration uses separate wiring for each signal channel.

PCB CCS

Typical structure:

• Printed circuit board

• Nickel tabs or conductive pads

• Aluminum busbar

• Heat-pressed insulation layers

• Structural support components

In this configuration, voltage and temperature signals are integrated into the PCB layout.

Features of Wire Harness vs PCB CCS

Wire Harness CCS

Key characteristics:

• Mature and widely used technology

• Stable and reliable signal transmission

• Independent wiring for voltage and temperature sensors

• Cost-effective for small and medium production volumes

• Simple structure and easy maintenance

Limitations:

• More internal wiring

• Larger installation space

• Lower automation compatibility

PCB CCS

Key characteristics:

• Integrated signal acquisition structure

• Lightweight and compact design

• Reduced wiring complexity

• Stable electrical performance

• High automation compatibility

• Suitable for large-scale production

Limitations:

• Higher initial tooling cost

• Less flexible for design changes after production

Applications of Wire Harness and PCB CCS

Both solutions are widely used in lithium battery systems across various industries.

Typical applications include:

• Commercial and industrial energy storage systems

• Containerized ESS

• Electric vehicle battery packs

• Modular lithium battery cabinets

• Backup power systems

In practice:

• Wire harness CCS is often used in cost-sensitive or lower-volume projects.

• PCB CCS is more common in automated, high-integration production environments.

Price of Wire Harness and PCB CCS

The cost of energy storage systems for renewable energy integration depends on several factors, including system capacity, storage duration, battery type, control software, installation conditions, and auxiliary equipment.

Pricing is usually quoted under international trade terms such as EXW, FOB, or CIF, depending on project location and logistics preferences. For a tailored quotation based on your specific project needs, it's best to consult directly with the supplier.

How to Select Between Wire Harness and PCB CCS?

Choosing between these two solutions depends on several project factors.

Choose wire harness CCS when:

• Budget is limited

• Production volume is moderate

• Traditional designs are acceptable

• Easy maintenance is required

Choose PCB CCS when:

• High integration is required

• Automated assembly is planned

• Compact module structure is needed

• Large production volumes are expected

The Supplier of Wire Harness and PCB CCS

Integrated CCS solutions based on wire harness or PCB structures are commonly used in modern ESS battery modules and large-capacity energy storage systems across commercial, industrial, and grid-scale applications.

If you are interested in Wire Harness and PCB CCS products or would like to learn more about battery module connection solutions, please contact sales@dagongess.com for further information.