Charging Heavy-Duty Electric Trucks with Sensata High Voltage Distribution Units
If there’s one thing rattling the foundations of the transport sector, it’s the electrification of heavy-duty vehicles. While the headlines often focus on passenger cars, the silent workhorses of our global supply chain—trucks—are undergoing a transformation of their own. At the centre of this shift is Sensata Technologies, whose High Voltage Distribution Units (HVDUs) are quietly enabling the megawatt charging revolution, now appearing in production on heavy-duty electric trucks.
With growing global regulations pushing manufacturers to curb fleet emissions, the pressure’s on to deliver robust, scalable, and safe electrified solutions for commercial transport. Sensata’s suite of HVDUs is not just a technical feat; it’s a strategic leap, directly addressing the needs of OEMs as they roll out their next generation of electric trucks capable of megawatt-hour (MWh) battery capacities and lightning-fast, multi-megawatt charging.
What Makes Sensata’s HVDUs Stand Out?
As battery sizes balloon—sometimes tipping the scales at a staggering 1 MWh—charging times and power delivery become mission-critical. Sensata’s answer? An array of Power Distribution Units (PDU), Charge Units (CU), and Charge PDUs (CPDU) engineered specifically to handle the complex demands of electrified commercial vehicles.
These aren’t off-the-shelf boxes, either. Sensata’s HVDUs are custom-designed for every application, integrating a host of in-house produced high-voltage components, including:
- Fuses and contactors for superior circuit protection
- Electric Vehicle Charge Controllers (EVCCs) to orchestrate safe, efficient charging
- Insulation Monitoring Devices (IMDs) to ensure electrical safety
- Current sensors for precise monitoring
- Advanced control electronics, all wrapped up in a compact footprint
Throw in liquid cooling systems, IP-rated enclosures, and highly optimised busbars and wiring, and you’ve got a system ready to thrive in the toughest environments—whether that’s a windswept highway or a bustling freight yard.
Tackling the Heat Head-On
When it comes to megawatt charging, heat is the enemy. Massive current flows can quickly generate temperatures that spell disaster for less robust designs. Sensata, however, has invested heavily in innovative thermal management solutions. Their HVDUs use sophisticated cooling systems to maintain optimal operating temperatures even during rapid charging or peak power draw.
What’s more, these systems are designed with longevity in mind. By keeping critical components cool, Sensata’s solutions help ensure a long service life, reducing maintenance and replacement costs for operators—a win-win in a sector where uptime is everything.
Rugged Reliability in Any Environment
Trucks don’t spend their lives coddled in laboratory conditions. Road salt, dust, vibration, and extreme weather are all part of the daily grind. Sensata’s HVDUs are built for real-world abuse, with IP-rated enclosures to shrug off water and contaminants, and robust construction to handle shocks and vibration without skipping a beat.
That focus on durability pays off for fleet owners and operators, who need assurances that electrified trucks will stand up to years of punishing service. The HVDUs’ resilience is key to unlocking the widespread adoption of electric trucks in logistics, construction, mining, and beyond.
The Dual Mandate
In heavy-duty applications, safety isn’t negotiable. High-voltage systems must protect both people and property, without sacrificing performance. Sensata’s design philosophy bakes safety features directly into every component. Built-in fuses, contactors, and insulation monitoring aren’t just add-ons—they’re integral to the system, ensuring safe operation whether the truck’s charging, discharging, or idling.
As Mark McBrine, Product Line Owner – Electrification, explained: “Our high voltage distribution units will play a crucial role in advancing the electrification of heavy vehicles, and we are proud to contribute to a more sustainable future on leading manufacturer’s next-generation trucks.”
A Game Changer for Fleet Electrification
Let’s talk numbers. Charging at up to 3 megawatts is no mean feat. For context, that’s enough juice to power a small neighbourhood—or to slash charging times for a heavy-duty truck, turning hours into minutes.
By integrating megawatt charging capability into production vehicles, Sensata’s HVDUs unlock the fast-turnaround potential that logistics operators crave. Downtime melts away, while operational flexibility surges. Suddenly, electric trucks can go head-to-head with diesel rivals on range, refuelling, and cost-effectiveness.
Brian Wilkie, Executive Vice President, Performance Sensing, Vehicle Business, put it this way: “The use of our megawatt charging solutions on electric trucks in production represents a significant milestone for Sensata’s electrification portfolio and highlights our commitment to innovation and to solving our customers’ toughest challenges.”
Under the Bonnet
It’s one thing to bolt together a system from off-the-shelf components. It’s quite another to deliver a suite of fully integrated solutions, engineered from the ground up to work in harmony. Sensata’s HVDUs exemplify this philosophy, incorporating high-voltage components, liquid cooling, advanced electronics, and space-saving design—all developed and manufactured in-house.
This vertical integration pays real dividends. Sensata can tailor each unit to the needs of specific OEMs, optimising every element for the job at hand. It’s a level of agility that lets Sensata respond quickly to customer requirements and emerging industry standards—an essential edge in the fast-moving world of vehicle electrification.
Regulatory and Market Drivers
The electrification of heavy-duty trucks isn’t just about shiny new tech. Governments worldwide are tightening emissions regulations, creating both challenges and opportunities for OEMs. In the EU, for instance, tough new CO2 standards are accelerating the shift towards battery electric vehicles in freight and logistics.
Industry giants are responding in kind. With Sensata’s HVDUs at their core, leading manufacturers are rolling out zero-emission trucks that don’t just tick regulatory boxes—they’re built for real-world duty cycles, and they’re already on the road.
Showcasing Innovation at ACT Expo
The spotlight will soon fall on Sensata at the Advanced Clean Transportation (ACT) Expo, running from 28 to 30 April in Anaheim, California. At booth 6811, the company’s HVDUs will be on full display, offering visitors a first-hand look at the technology powering the next generation of heavy-duty electric vehicles.
For those attending, it’s a rare chance to get up close with the nerve centre of tomorrow’s freight revolution—a system designed not just to keep pace, but to set the standard.
Powering Progress Worldwide
Sensata Technologies brings a century-old legacy to the table, but there’s nothing old-fashioned about its outlook. With over 18,000 employees in 14 countries, Sensata is a powerhouse of industrial technology. Its broad portfolio covers everything from mission-critical sensors to advanced electrical protection components and sensor-rich solutions.
Serving a global customer base across automotive, heavy vehicle & off-road, industrial, and aerospace markets, Sensata is laser-focused on delivering the safety, efficiency, and reliability today’s manufacturers demand.
Bright Roads Ahead for Electric Trucks
Sensata’s High Voltage Distribution Units aren’t just engineering marvels; they’re key enablers in the transition to a cleaner, more sustainable freight sector. By making megawatt charging a practical reality for production vehicles, Sensata is helping industry giants—and the world—move closer to zero-emissions transport.
The future is here, and with Sensata powering the charge, it’s brighter than ever.
