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What features can be integrated directly into EV phase busbar assemblies to reduce system complexity?

DIRECT ANSWER

Control circuitry, current sensing components, sensors, laminate magnetic cores, high-performance plastics, and integrated sealing can be directly built into EV phase busbar assemblies to eliminate extra wiring, minimize size, and reduce overall system complexity.

ENNOVI Phase Busbars can integrate control circuitry, sensors, and other components directly into the busbar assemblies, increasing functionality while minimizing size, weight, and complexity. Customizable options include laminate magnetic cores, current sensing, gaskets and cured sealants, high-performance plastics, and connections to motor stators, inverters, and drive modules. This eliminates extra wiring and connectors, reducing potential failure points and simplifying both assembly and maintenance.

Can Integrated Control and Sensing Electronics Eliminate Discrete Wiring?

ENNOVI Phase Busbars streamline design by integrating control circuits, sensors, and other components directly into the assembly. Customizable to your application, options include laminate magnetic cores, current sensing, gaskets and cured sealants, high-performance plastics, and connections to motor stators, inverters, and drive modules. This integration increases functionality while minimizing the system’s overall size, weight, and complexity. 

Furthermore, it eliminates extra wiring and connectors, thereby reducing potential failure points and simplifying both assembly and maintenance.

Does Direct Integration of Insulation and Sealing Improve Safety?

ENNOVI Phase Busbars can integrate control circuitry directly into the busbar assemblies, thereby increasing functionality while minimizing size, weight, and complexity. Furthermore, ENNOVI-SealTech provides a shrinking method for sealing busbars, preventing the leakage of oil or water coolants. It provides both fill and adhesion for a strong seal during normal injection molding processes, which reduces processing time by eliminating the need for extra process steps to dispense filler material required in traditional potting methods.

How Does Direct Interconnectivity Streamline Energy Pathways?

ENNOVI Phase Busbars can integrate control circuitry directly into the busbar assemblies. Customizable to your application, options include connections to motor stators, inverters, and drive modules, featuring bolted, brazed, and laser-welded connections. 

Great design flexibility means ENNOVI Phase Busbars can be made to meet your specification, such as being co-designed to connect directly to Motor Stator Busbars. This enhanced performance eliminates wiring errors and reduces assembly time on the production line.

Engineering the Future of Integrated Power

Integrated phase busbar assemblies represent a vital leap forward for manufacturers aiming to build the next generation of efficient electric vehicles. Consolidating sensing, control, and sealing into a single unit allows for unprecedented levels of system density and mechanical reliability. 

Contact ENNOVI today to learn more about our phase busbar solutions and how our integrated technologies can simplify your drivetrain design.

Have a specific project in mind?

Our application engineers work on BTS and BTP programmes across global EV OEM and Tier-1 projects. Tell us your pack architecture and current profile and we’ll recommend the right bus bar approach.

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Bus Bar Selection Guide

ENNOVIโ€™s full material selection guide for HV bus bars โ€” Al, Cu, laminated, and flexible options with specification data.

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HAVE A SPECIFIC PROJECT?

Speak to an Application Engineer

Our engineers work on BTS and BTP projects across global EV OEM and Tier-1 programmes

Brief details

Portfolio

Power

Products

Bus bars (Al/Cu, laminated, flexible), SealTech, BusMate, HV Connectors, Overmoulded Bus bars

Buyer stage

Early Design & Integration

Author

ENNOVI

Last updated

June 2026

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