Custom CCS Solutions（CCS）

Custom CCS Integrated Interconnection Solutions
Full laser welding inspection, high integration and lightweight design, compatible with cylindrical, prismatic and pouch batteries.

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CCS

CCS— FPC Flexible Printed Circuit Solution

An integrated data acquisition and connection solution for battery systems, enabling real-time monitoring and precise management of critical cell data. Adopting a highly integrated structural design, it improves system reliability and safety, and supports battery performance optimization and full life cycle management.

Optimized Solution for CCS

Integrated Process Optimization

Material Selection Optimization

Structural Design Optimization

Custom Solution Optimization

Integrated Process Optimization

【Higher Integration】: The FPC, sampling system and busbar are highly integrated. Compared with traditional wire harness solutions, it eliminates redundant components and connection points, and simplifies assembly procedures.

Material Selection Optimization

【Higher Safety】: Relying on long-term strategic supply chain cooperation, stable supply of high-quality materials is guaranteed, balancing performance, safety and project economy. Adopting a standardized isolation structure design and high-mechanical-strength, temperature-resistant insulating materials for isolation layers, it significantly reduces short-circuit and failure risks and enhances overall safety.

Structural Design Optimization

【Lightweight Design】: Adopting lightweight materials and replacing traditional wire harnesses with FPC, the solution greatly reduces overall weight and improves the space utilization rate of battery packs.

【Reliable Transmission】: The integrated design reduces connectors and harness interference. Laser welding technology enhances structural connection stability, shortens signal paths, and delivers higher signal stability and system reliability.

Custom Solution Optimization

FPC Flexible Printed Circuit — Core Advantages

The optimization scheme of the new CCS integrated busbar and FPC flexible printed circuit covers multiple dimensions, including integrated process, material selection, structural design, process improvement and cost optimization.

Ultra-lightweight Structure

Supplied as an integrated assembly for direct module installation. Adopting high-performance polyimide material with thinner substrate design, the solution saves internal module wiring space and reduces overall weight compared with traditional wire harnesses and rigid PCBs.

Superior Flexibility

The FPC can be moderately bent to avoid structural protrusions of the module, delivering higher layout flexibility compared with rigid PCB solutions. Unlike FFC-based CCS schemes, the integrated one-piece circuit structure eliminates segmented plug-in connections and reduces the risk of signal contact failure. It is highly suitable for narrow installation environments inside blade battery CTP packs and compact industrial and commercial energy storage modules.

Superior Reliability

Supported by the company’s CNAS‑accredited laboratory and UL/TUV witness‑test qualifications, FPC‑type CCS covers complete test items and complies with IATF16949 automotive‑grade development and control requirements. For energy‑storage products, it meets domestic and overseas energy‑storage safety specifications. Optimized routing and bending‑zone design reduce stress concentration, delivering better performance under vibration conditions than conventional solutions.

Automation‑compatible

Dedicated FPC‑CCS Production Line: Laser Welding → Insulation Coating → AOI Visual Inspection → Full Continuity & Withstand‑voltage Testing. Optimized for medium‑ and long‑term high‑volume energy storage and automotive projects, it supports SMT, automatic mounting and other processes to boost production efficiency and reduce manual reliance.

Enhanced Efficiency

57%

Enhanced Efficiency

Cost Saving

68%

Cost Saving

Higher Production Throughput

60%

Higher Production Throughput

Reduced Labor Overhead

45%

Reduced Labor Overhead

Automated Workshop

Production is carried out via automated production lines and standardized processes to ensure stable and controllable manufacturing procedures. Centered on CCS integrated busbar manufacturing, it covers key processes including SMT mounting, component assembly and inspection. Combined with the MES system, digitalized production management and full‑process traceability are realized. Cooperating with the SAP material management system, a closed‑loop control mechanism from raw materials to finished products is established to guarantee production stability and product consistency.

Digital Workshop

The workshop is fully deployed with the MES manufacturing execution system. Each CCS product is assigned a unique serial number. Raw material batches, equipment process parameters, laser welding profiles, AOI images and electrical performance test data are permanently archived to realize full‑life‑cycle traceability from raw materials to finished products and support customer traceability audits.

Intelligent Manufacturing Workshop

From precision component processing to intelligent integrated manufacturing, ZHONGHUI RUIDE CCS smart manufacturing workshop produces each set of integrated busbars in accordance with automotive‑grade manufacturing standards. Through continuous automation upgrading, digital traceability and rigorous full‑process quality control, we deliver high‑safety, high‑consistency, mass‑producible CCS integrated busbar products for global energy‑storage and new‑energy customers.

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