Transition to high-voltage electric vehicle architectures eased by Sensata's latest contactor innovation
Sensata Technologies, a leading global provider of sensors, electrical protection components, and control systems, has launched a new innovation to simplify the transition from 400V to 800V electric vehicle architectures: the High Efficiency Contactor (HEC).
The HEC offers a range of key benefits and features designed to address the challenges of high-performance and safety-critical applications.
Improved Safety and Reliability
One of the HEC's most significant advantages is its ability to provide selective isolation of battery packs. This feature extends battery life, improves system reliability, and reduces the risk of vehicle stranding in critical situations.
High Current Capacity and Efficiency
The HEC supports continuous currents above 1,000 A with a low and stable contact resistance of approximately 50 µΩ. This feature ensures high efficiency and minimizes energy loss, contributing to the overall performance and longevity of the electric vehicle.
Robust Mechanical Design
The HEC boasts a robust mechanical design, including a mechanical interlock of three high-voltage contactor poles. This design prevents incorrect switching, eliminating risks such as software bugs, welded contacts, or mechanical shock-induced faults.
Exceptional Durability
The HEC is exceptionally durable, withstanding short-circuit events up to 25 kA and mechanical shocks over 90 g. This durability makes it suitable for safety-critical and high-performance applications.
Reduced System Component Count
The HEC's compact, lightweight, and bi-stable design reduces the system component count by more than 50%. This reduction simplifies system design, reduces costs, and supports scalable next-generation electrification platforms.
Real-Time Diagnostics and Versatile Battery Configuration Support
An integrated ASIL-D compliant position sensor enables real-time diagnostics, enhancing safety and reliability monitoring. The HEC also supports versatile battery configuration, accommodating up to five battery states for various electric vehicle architectures.
Future-Ready Compatibility
The HEC is compatible with advanced EV and energy systems, including Vehicle-to-Grid (V2G) functionality, megawatt (MW) charging, and the North American Charging Standard (NACS/J3400), making it future-ready.
Brian Wilkie, EVP, Vehicle Business at Sensata Technologies, stated that the HEC launch reflects Sensata's commitment to solving real-world electrification challenges.
The HEC enables 800V EVs to charge at 400V charging stations without the need for costly boost converter systems. This compatibility addresses key challenges in 800V EVs, such as pack imbalance due to aging or uneven usage and loss of drive capability if one pack fails.
Sensata Technologies is hosting a webinar titled "Solving The 400V/800V Charging Compatibility Challenge In Next-Gen EVs". The webinar is open for registration.
By powering safer, more efficient vehicles with seamless charging, the HEC is set to accelerate the adoption of next-generation platforms.
The High Efficiency Contactor (HEC) from Sensata Technologies is compatible with advanced EV and energy systems like Vehicle-to-Grid (V2G) functionality, megawatt (MW) charging, and the North American Charging Standard (NACS/J3400), ensuring its future-readiness.
The HEC's robust mechanical design, including a mechanical interlock of three high-voltage contactor poles, prevents incorrect switching, eliminating risks such as software bugs, welded contacts, or mechanical shock-induced faults, enhancing safety in high-performance applications.
