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

Sensata Technologies has launched a High Efficiency Contactor (HEC) designed to simplify the transition from 400 V to 800 V electric vehicle architectures.

The HEC enables seamless compatibility with legacy and next-generation charging infrastructure, according to the company, allowing 800 V EVs to charge at 400 V charging stations without the need for costly boost converter systems.

In addition to standard 400 V/800 V switching, the HEC supports independent access to either of the two 400 V battery packs, enabling functions like battery balancing and limp-home mode. This addresses key challenges in 800 V EVs, such as pack imbalance due to aging or uneven usage and loss of drive capability if one pack fails.

By allowing selective isolation of each pack, the HEC helps extend battery life, improves reliability and reduces the risk of stranding in critical situations.

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The HEC integrates three high-voltage contactor poles into a design featuring mechanically synchronized contacts, providing a 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. Energy loss and heat generation are negligible due to its bi-stable design and ultra-low contact resistance (<50μΩ).

The contactor reduces system component count by over 50%, as no extra cooling or special equipment are required. It can withstand short-circuit events up to 25 kA and mechanical shocks over 90 g.

Engineered for high-performance and safety-critical applications, the HEC supports continuous currents over 1,000 A. Real-time diagnostics are enabled through an integrated ASIL-D compliant position sensor. Beyond battery reconfiguration, the contactor is also compatible with 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,” said 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.”

Source: Sensata Technologies