Sensata Technologies has introduced OmniNode, a patent-pending, off-the-shelf high-voltage power distribution platform that consolidates switching, protection, sensing, diagnostics, communications and charging into a single system for Class 5 and above battery-electric trucks and buses. The OmniNode combines contactors, fuses and current sensors from Sensata’s existing portfolio into one system-level unit, replacing the multiple discrete components OEMs typically integrate separately. According to the company, the approach reduces custom engineering, shortens development timelines and allows one power distribution design to be reused across several vehicle platforms.
Highlights
- Six functions in one platform: OmniNode integrates high-voltage switching, circuit protection, sensing, diagnostics, communications and DC charging.
- Target applications: Battery-electric on- and off-road commercial vehicles, including Class 5 and above trucks and buses.
- Built from existing components: The platform draws on Sensata’s contactor, fuse and current-sensor product lines.
- Patent-pending, off-the-shelf design: Intended to replace custom-engineered power distribution assemblies with a standardized building block.
Why Consolidate High-Voltage Power Distribution?
As fleets and OEMs move to battery-electric heavy vehicles, Sensata identifies high-voltage system complexity, cost and scalability as the main obstacles. Managing switching, protection, monitoring and control through separate components increases integration effort, validation requirements and overall system complexity, the company says.
OmniNode addresses this with a standardized approach to DC charging, high-voltage switching and circuit protection. Sensata positions the unit as a flexible building block that lets OEMs optimize system packaging while keeping charging and power distribution on a common platform. The product follows the company’s earlier moves in this space, including its PyroFuse for high-voltage safety and the High Efficiency Contactor for 400V and 800V charging.
“Commercial vehicle manufacturers are under pressure to scale electrification programs while managing increasing system complexity,” said Brian Wilkie, Executive Vice President and President of Aerospace, Defense and Commercial Equipment at Sensata Technologies. “With the OmniNode, we are delivering an integrated, off-the-shelf approach that helps engineers simplify power distribution architecture, accelerate development timelines and bring greater consistency and efficiency to vehicle platform design.”
Key Features
- Integrated high-voltage functionality: Switching, protection, sensing, diagnostics, communications and charging consolidated within one system.
- Simplified integration and validation: Sensata says the platform reduces engineering and validation effort and accelerates OEM development cycles.
- Scalable architecture for platform reuse: Supports standardized power distribution across vehicle programs while allowing configuration for different applications.
Commercial EV Applications
OmniNode is designed for battery-electric on- and off-road commercial vehicle applications, including Class 5 and above trucks and buses, where the company says reliable management of charging and high-voltage power distribution directly affects vehicle performance and uptime. Sensata frames the system-level approach as a way for OEMs to streamline sourcing decisions, reduce validation burden and deploy new vehicle platforms more efficiently, while preparing for future power and charging requirements.
Sensata will present the platform and the broader challenges of commercial EV power distribution in an upcoming ChargedEVs webinar, Simplifying Commercial EV Power Distribution with Integrated Off-the-Shelf Solutions.
