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04 / Electronics · PCB Design

EV Safety-System PCBs

Team: Tufts Electric Racing Discipline: PCB design & mixed-signal electronics Date: 2024

Two boards that keep a Formula-Hybrid Electric race car safe — a high-current fusebox with blown-fuse indication and a fail-safe interlock latch system that keeps the safety circuit energized only when every condition checks out.

Overview

As part of Tufts Electric Racing's commitment to safety and regulatory compliance, I designed and developed critical safety-system PCBs for our high-voltage electric race car. These boards monitor, control, and protect both the vehicle and driver across competition and testing.

Fusebox PCB

Fusebox PCB design
Fusebox PCB — circuit layout and component placement for high-voltage protection.

The fusebox serves as a critical protection and distribution hub for the vehicle's electrical systems. It incorporates multiple fuse circuits — each with a visual indicator for a blown fuse — and is designed to handle high-current loads while staying safe under fault conditions.

Fully populated fusebox PCB
Fully populated fusebox PCB — components, fuses, and final assembly ready for vehicle integration.

Safety interlocks PCB

The safety interlocks keep the safety system energized only when no faults are present. I designed active-high and active-low latches for use with different sensor types — motor controller, BMS, and high-voltage connection interlock fault signals. The circuits always start in the disconnected state at power-up and only energize when every safety condition is met. They're fail-safe by construction: any loss of power or fault condition immediately de-energizes the system.

Active-high latch circuit design
Active-high latch — PNP-based fault signal processing & interlock logic.