Sunday, July 27, 2025

Charged EVs | Sensata’s new contactor facilitates the transition to 800-volt EV architectures

Sensata Applied sciences has launched a Excessive Effectivity Contactor (HEC) designed to simplify the transition from 400 V to 800 V electrical car architectures.

The HEC permits seamless compatibility with legacy and next-generation charging infrastructure, in line with the corporate, permitting 800 V EVs to cost at 400 V charging stations with out the necessity for pricey increase converter programs.

Along with normal 400 V/800 V switching, the HEC helps impartial entry to both of the 2 400 V battery packs, enabling capabilities like battery balancing and limp-home mode. This addresses key challenges in 800 V EVs, similar to pack imbalance attributable to growing old or uneven utilization and lack of drive functionality if one pack fails.

By permitting selective isolation of every pack, the HEC helps lengthen battery life, improves reliability and reduces the danger of stranding in vital conditions.

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Fixing The 400 V/800 V Charging Compatibility Problem In Subsequent-Gen EVs

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The HEC integrates three high-voltage contactor poles right into a design that includes mechanically synchronized contacts, offering a secure and extremely environment friendly switching mechanism.

The design removes the danger of brief circuits that may happen in conventional battery switching programs with a number of contactors, which can be brought on by software program errors, welded contacts, or mechanical shocks. Power loss and warmth technology are negligible attributable to its bi-stable design and ultra-low contact resistance (<50??).

The contactor reduces system part depend by over 50%, as no additional cooling or particular gear are required. It could actually face up to short-circuit occasions as much as 25 kA and mechanical shocks over 90 g.

Engineered for high-performance and safety-critical functions, the HEC helps steady currents over 1,000 A. Actual-time diagnostics are enabled by way of an built-in ASIL-D compliant place sensor. Past battery reconfiguration, the contactor can be suitable with vehicle-to-grid (V2G) programs, megawatt (MW) charging, and the North American Charging Customary (NACS/J3400).

“The launch of the HEC displays Sensata’s dedication to fixing real-world electrification challenges with revolutionary, environment friendly options,” mentioned Brian Wilkie, EVP, Car Enterprise at Sensata Applied sciences. “Our HECs energy safer, extra environment friendly automobiles with seamless charging, making EVs extra sensible and accelerating the adoption of next-generation platforms.”

Supply: Sensata Applied sciences


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