Key Takeaways
- Sensata Technologies launched the FaultBreak high-voltage contactor for simplifying fault management in EV power systems.
- The FaultBreak offers a resettable solution, reducing component count by over 50% compared to traditional systems.
- It enhances uptime and system safety while lowering warranty costs and design complexity.
Innovative High-Voltage Solution for EVs
Sensata Technologies has introduced the FaultBreak high-voltage contactor, a significant innovation for electric vehicle (EV) power systems. This device functions as a passive, resettable fault-protection component, merging the roles of a fuse and a contactor to streamline high-voltage fault management and boost efficiency in EV architectures.
The FaultBreak has demonstrated effective fault-clearing capabilities, validated for up to 16 kA at 1 kV. Operating with low contact resistance, it minimizes power loss, contrasting with traditional single-use fuse technologies. Upon encountering temporary or nuisance faults, the FaultBreak can be reset, enhancing vehicle uptime and potentially decreasing warranty claims.
Sensata emphasizes that by consolidating protective functions, the FaultBreak can significantly reduce the number of components needed. Specifically, it can eliminate over 50% of the components typically found in traditional fuse-and-contactor systems. This reduction allows for the removal of pyrofuses, busbars, and low-voltage harnessing from the designs, which simplifies the system. Additionally, this innovation avoids the necessity for complex electronics, ensuring compliance with ISO-26262 safety standards.
The device’s capabilities also contribute to minimized downtime and reduced warranty costs, as it allows for rapid recovery from recoverable fault events. This not only increases the vehicle’s reliability during operation but also provides significant advantages in overall production and maintenance costs.
Markus Schwabe, Executive Vice President of Automotive at Sensata Technologies, remarked, “Our FaultBreak contactor represents an important advancement in high voltage protection. It helps our customers build electric vehicles that are safer, more dependable, and more economical to produce and maintain.”
Additionally, Sensata will be hosting a webinar on March 11, aimed at sharing expert insights about managing high magnitude fault currents, improving system safety, and simplifying EV power architectures. This interactive session is designed for industry professionals seeking to enhance their understanding and application of these innovative technologies.
In summary, Sensata Technologies’ FaultBreak offers a dual benefit—safety and efficiency—forming a crucial component for future EV developments. By modernizing high-voltage fault management, Sensata paves the way for more effective and reliable electric vehicle designs.
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