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Sensata Technologies has announced the launch of its innovative High Efficiency Contactor (HEC), a cutting-edge solution engineered to resolve a critical challenge in the electric vehicle industry. This new device simplifies the transition between 400V and 800V EV architectures, enabling seamless compatibility with both legacy and next-generation charging infrastructures while enhancing safety, efficiency, and system design.
Key Highlights
- Universal Charging Compatibility: The HEC allows 800V electric vehicles to charge efficiently at the more common 400V charging stations without needing costly and complex boost converter systems.
- Simplified Design: It reduces the system’s component count by over 50% compared to conventional battery switching methods, resulting in a more compact and lightweight solution.
- Inherently Safe Operation: A unique, patent-pending mechanical design with synchronized contacts eliminates the risk of short circuits that can occur from software errors or hardware failures in traditional systems.
- Enhanced Battery Performance: The contactor supports critical functions like battery balancing and a “limp-home” mode, which extends battery life and ensures the vehicle remains operational if one battery pack fails.
- Superior Efficiency: A bi-stable design requires no power to hold its position, and an ultra-low contact resistance of less than 50μΩ minimizes energy loss and heat generation.
Addressing a Critical EV Challenge
As the automotive market increasingly shifts to 800V systems for faster charging speeds and better performance, a significant hurdle has emerged: compatibility with the vast network of existing 400V chargers. Sensata’s HEC directly addresses this issue by enabling the vehicle’s battery system to safely reconfigure itself between 400V for charging and 800V for driving. This innovation removes a major barrier to the adoption of next-generation EV platforms.
Advanced Safety and System Efficiency
The High Efficiency Contactor integrates three high-voltage poles into a single, compact unit. Its mechanically interlocked design provides a fail-safe switching mechanism that is inherently protected against the dangerous short circuits that can plague systems using multiple, independently controlled contactors. This robust construction is engineered to withstand short-circuit events up to 25 kA and mechanical shocks over 90 g, ensuring best-in-class safety and reliability. Furthermore, its high-efficiency design requires no extra cooling equipment, simplifying integration and reducing overall vehicle weight.
Unlocking Flexible Battery Management
Beyond standard voltage switching, the HEC offers a unique advantage by allowing independent access to the two 400V battery packs that comprise an 800V system. This capability enables crucial battery management functions. Battery balancing can be performed to counteract imbalances caused by aging or use, extending the overall life of the pack. Additionally, a “limp-home” mode can isolate a malfunctioning pack, allowing the vehicle to continue operating on the remaining one and reducing the risk of a driver becoming stranded.
A Versatile, Future-Ready Solution
Engineered for high-performance applications, the HEC supports continuous currents exceeding 1000 A and features an integrated ASIL-D compliant position sensor for real-time system diagnostics. Its versatility extends beyond battery reconfiguration, as it is also compatible with emerging technologies like Vehicle-to-Grid (V2G) systems, Megawatt (MW) charging, and the North American Charging Standard (NACS/J3400).
“The launch of the HEC reflects Sensata’s commitment to solving real-world electrification challenges with innovative, efficient solutions,” stated Brian Wilkie, EVP, Vehicle Business at Sensata Technologies. “Our HECs power safer, more efficient vehicles with seamless charging, making EVs more practical and accelerating the adoption of next-generation platforms.”
To learn more about the technical capabilities of the new High Efficiency Contactor, visit www2.sensata.com/HECs. To hear from company experts on overcoming infrastructure challenges, register for the upcoming webinar at www2.sensata.com/HEC-webinar.
About Sensata Technologies
Sensata Technologies is a global industrial technology company that strives to create a safer, cleaner, more efficient, and electrified world. Through its broad portfolio of mission-critical sensors, electrical protection components, and sensor-rich solutions, Sensata helps its customers address increasingly complex engineering and operating performance requirements. With more than 18,000 employees and global operations in 14 countries, Sensata serves customers in the automotive, heavy vehicle & off-road, industrial, and aerospace markets. Learn more at www.sensata.com.
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