Sensata High Efficiency Contactor Revolutionises EV Charging Compatibility
As electric vehicles (EVs) race toward mainstream adoption, the challenge of bridging legacy charging infrastructure with next-gen architectures has become more pressing than ever. Sensata Technologies has stepped into this gap with a game-changing innovation: the High Efficiency Contactor (HEC).
This isn’t just a new piece of kit. It’s a fundamental leap in how battery systems can adapt to evolving voltage standards. With the EV industry rapidly shifting toward 800V architectures for faster charging and improved powertrain efficiency, legacy 400V charging stations remain stubbornly dominant. That’s where Sensata’s HEC becomes a lynchpin for seamless compatibility.
“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.”
400V/800V interoperability
At the heart of the HEC’s promise lies its ability to enable real-time reconfiguration of an EV battery between 400V and 800V states. Traditionally, doing this required bulky, expensive boost converters that not only added to costs but also to system complexity and weight. Sensata’s HEC eliminates the need for such components.
Instead, the HEC uses a patent-pending design that incorporates three high-voltage contactor poles with mechanically synchronised contacts. This clever mechanism ensures smooth switching without the risk of short circuits, which can be triggered by common faults such as software errors, welded contacts, or mechanical shocks.
The result? A system that’s inherently safer, significantly more efficient, and drastically lighter.
Unlocking critical battery functions
One of the standout features of the HEC is its support for independent access to either of the two 400V battery packs in an 800V configuration. This opens the door to vital functionalities:
- Battery balancing: Helps correct pack imbalance caused by age or uneven charging cycles.
- Limp-home mode: Allows the vehicle to operate on one functioning pack if the other fails.
- Selective isolation: Extends battery life and improves reliability during critical drive conditions.
This level of granularity in pack management is a significant stride forward for manufacturers aiming to build EVs that are both robust and resilient.
Compact, lightweight, and astonishingly efficient
By integrating the functionality of multiple traditional contactors into one tightly engineered unit, the HEC reduces the overall component count by over 50%. That means less wiring, fewer potential points of failure, and a smaller system footprint.
Sensata’s contactor also boasts ultra-low contact resistance, clocking in at less than 50 micro-ohms. With its bi-stable design, it requires no holding power to maintain position, minimising energy loss and heat generation. No additional cooling systems are needed, making it an ideal choice for lightweight EV platforms and performance-focused applications.
Safety first, second and third
Safety isn’t just a checkbox; it’s been baked into the HEC’s design from the ground up. It can withstand mechanical shocks exceeding 90g and short-circuit events up to 25kA. For added protection, the integrated ASIL-D compliant position sensor ensures real-time diagnostics and state monitoring, aligning with the most stringent safety requirements in automotive standards.
By removing the margin for switching errors and eliminating arc risk, Sensata’s HEC positions itself as a benchmark in high-voltage switching for safety-critical EV systems.
Engineered for tomorrow’s mobility ecosystem
Far from being a one-trick pony, the HEC’s design enables broad compatibility with emerging technologies:
- Vehicle-to-Grid (V2G): Supports bidirectional energy flow for future grid integration.
- Megawatt charging: Built to scale up for heavy-duty EV applications.
- North American Charging Standard (NACS/J3400): Fully compliant with the growing NACS ecosystem.
This flexibility allows OEMs to future-proof their platforms, offering extended lifecycle value to both vehicle manufacturers and end-users.
Designed with global reach in mind
Sensata Technologies isn’t new to this game. With over 18,000 employees across 14 countries, they bring a global footprint and deep expertise in mission-critical systems. Their portfolio spans automotive, off-road, aerospace, and industrial markets, positioning them as a key player in electrification.
Their strategy hinges on enabling safer, cleaner, and more efficient transportation through smart engineering. The HEC is the latest testament to this ethos—a modular, high-performance component that ticks all the right boxes for modern mobility challenges.
Why this matters for the EV market
EV adoption isn’t just about batteries and motors. It’s about the invisible hardware in between that ensures everything talks to each other smoothly. With infrastructure still catching up, particularly in regions where 800V charging is rare, having hardware that can switch voltages on the fly is nothing short of revolutionary.
The HEC empowers automakers to scale their platforms without sacrificing backward compatibility. It reduces weight, boosts efficiency, slashes costs, and offers peace of mind in high-risk scenarios. For fleet operators, private EV owners, and infrastructure developers, that translates to fewer headaches and more uptime.
A leap forward for sustainable transport
Sensata’s HEC is more than a component—it’s a catalyst. By making high-voltage EV architectures more accessible and less complex, it smooths the path to a truly electrified future. And by enabling features like V2G and limp-home operation, it underpins a broader, more resilient energy and transport network.
From reduced component count to increased safety margins, this tiny device packs a powerful punch. And with the world watching for scalable EV solutions, innovations like the HEC shine a spotlight on the behind-the-scenes engineering that makes modern mobility work.
Powering the future, one smart switch at a time
The shift to electrification hinges on reliability, adaptability, and performance. Sensata’s High Efficiency Contactor is a timely reminder that sometimes, it’s the smallest components that make the biggest difference.
