Sensata Technologies has introduced its STEV series of high-voltage contactors designed for battery electric and plug-in hybrid vehicles. The components support applications ranging from passenger cars to Class 8 heavy-duty trucks.
The STEV series addresses critical switching requirements in electrified powertrains. Contactors serve as high-voltage switches that control power flow between the battery pack and systems including inverters and onboard chargers.
Highlights
- Scalable platform coverage: STEV contactors support vehicles from PHEVs to Class 8 trucks, enabling OEMs to standardize components across multiple vehicle lines.
- Current ratings from 150 A to 600 A: Hermetic sealing and modular designs accommodate diverse powertrain architectures with short-circuit withstand capability exceeding 20 kA.
- Global manufacturing footprint: Regional production across North America, Europe, and Asia supports supply chain resilience and localization requirements.
- Automotive quality compliance: Products meet APQP processes and OEM certification standards for integration into global platforms.
Contactor Function in EV Architecture
High-voltage contactors open and close electrical circuits thousands of times during a vehicle’s operational life. In EVs, these components enable safe power transfer between the battery and drivetrain systems.
Performance characteristics directly affect vehicle safety, efficiency, and long-term reliability. Contactors form a critical element of the protective architecture in modern electric vehicles.
Platform Scalability
The STEV series scales across vehicle segments, including:
- Plug-in hybrid passenger vehicles
- Battery electric pickup trucks
- Class 8 heavy-duty commercial trucks
This scalability allows manufacturers to deploy consistent switching technology across product lines while reducing development time and integration complexity.
Customization and Compliance
Sensata engineered the STEV platform with configurable options to address specific application requirements. The core switching technology reflects years of iterative development.
“We don’t just manufacture components. We engineer solutions with our customers, adapting our STEV contactors to the unique demands of leading OEM’s applications,” said Markus Schwabe, EVP, Automotive and Aftermarket at Sensata Technologies.
The contactors comply with APQP processes and meet OEM certification requirements for global vehicle platform integration.
Technical Specifications
STEV contactors deliver low contact resistance and reduced heat generation. Key specifications include:
- Assembly options: Single or dual configurations for diverse power distribution architectures
- Bidirectional capability: Select models feature non-polarity main contacts for advanced power system designs
- Sealing: Hermetic ceramic construction with IP67 ingress protection on specific variants
- Continuous current ratings: 150 A to 600 A
- Short-circuit withstand: Greater than 20 kA
- Dielectric strength: Coil-to-contact rating up to 3.0 kV
- Insulation resistance: 1000 MΩ at 1000 VDC
Global Manufacturing Network
Sensata operates engineering and manufacturing facilities across North America, Europe, and Asia. This footprint enables regional production capabilities and supports OEM localization strategies while mitigating supply chain risk.
The STEV series expands Sensata’s electrification portfolio for EV and PHEV applications.
For additional product information, visit www2.sensata.com/STEV.
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