Lowers component count by more than 50% compared to conventional battery switching systems, while supporting safety, efficiency, and system integration.
Sensata Technologies has launched its High Efficiency Contactor (HEC), developed to support the transition from 400V to 800V electric vehicle (EV) architectures. The HEC is compatible with both existing and next-generation charging infrastructure and is designed to support safety, efficiency, and system integration.
As EV systems move toward 800V architectures to support faster charging and greater efficiency, maintaining compatibility with existing 400V charging infrastructure remains an important consideration. Sensata’s HEC supports this by enabling battery reconfiguration between 400V and 800V.
Alongside standard 400V/800V switching, the HEC allows independent access to each of the two 400V battery packs. This supports functions such as battery balancing and limited operation in the event of a pack failure. It helps manage issues related to pack imbalance caused by aging or uneven use and maintains partial drive capability if one pack is unavailable. This selective isolation can support battery longevity and operational reliability.
The HEC integrates three high-voltage contactor poles into a patent-pending design featuring mechanically synchronized contacts, providing an inherently safe and highly efficient switching mechanism. The design removes the risk of short circuits that can occur in traditional battery switching systems with multiple contactors, which may be caused by software errors, welded contacts, or mechanical shocks, resulting in best-in-class safety and reliability. Energy loss and heat generation are negligible due to its bi-stable design and ultra-low contact resistance (<50μΩ).
Key benefits of Sensata’s High Efficiency Contactor include:
- Flexible configuration:Â Supports standard battery configurations (Series-800V, Parallel-400V, Open-Isolated) and single-pack selection (A-only / B-only) for battery balancing and limp-home modes.
- Inherently safe:Â Unique mechanical design prevents incorrect switching, eliminating short-circuit risk.
- Robust performance:Â Withstands short-circuit events up to 25 kA and mechanical shocks over 90 g.
- Compact and lightweight:Â Reduces system component count by over 50%; no extra cooling or special equipment required.
- High efficiency: Bi-stable design requires no holding power; extremely low contact resistance (less than 50 µΩ) minimizes energy loss and heat generation.
Engineered for high-performance and safety-critical applications, the HEC supports continuous currents over 1000 A. Real-time diagnostics are enabled through an integrated ASIL-D compliant position sensor. Beyond 400V/800V battery reconfiguration, Sensata’s HEC is also compatible with Vehicle-to-Grid (V2G) systems, Megawatt (MW) charging, and the North American Charging Standard (NACS/J3400), making it a versatile solution for modern EV and energy ecosystems.
For more information, visit sensata.com.
