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Electrification Solutions for Electric and Hybrid Electric Vehicles (EV/HEV)

The advantages of Electric and Hybrid Electric Vehicles (EV/HEV) have been long-known. To the everyday driver, they offer reduced fuel costs. For the environment, they utilize renewable energy and offer reduced emissions. Challenges associated with EV/HEV stem from a limited availability of technologies to enable the use of electricity as a fuel source in a safe and cost-effective manner.

With our vast automotive expertise, engineering resources and manufacturing capabilities, Amphenol Sensors offers various sensor solutions that enable automotive manufacturers to accelerate the electrification of vehicles around the world.

Temperature    Pressure    Gas   Level    Position

1. Battery Pack

Consists of a cluster of individual batteries that serve as the primary fuel source of the vehicle, replacing hydrocarbon fuels used in conventional ICE automobiles.
● Temperature Sensors

2. Thermal Runaway

Occurs when battery cells exceed allowable operating temperature causing an explosion/fire, which then propagates, or spreads, to other cells within the battery pack.
● Temperature Sensors
 Pressure Sensors
Gas Detection Sensors

3. Cell Connection System (CCS)

Used as top cover of the battery cell to provide connectivity with the Battery Management System (BMS).
Temperature Sensors

4. Power Inverter / E-motor

Converts higher voltage DC electricity to lower voltage AC electricity that is required to power the electric motor.
Temperature Sensors
Inductive Position Sensors

5. High Voltage Charger Connector

Connects the high voltage source to charge the battery within the vehicle.
Temperature Sensors

6. Motor Coil

Wire coils that generate a magnetic field and conduct electric current. The interaction between the two generates rotation of the motor shaft and the actual conversion of electrical to mechanical energy.
Temperature Sensors

7. Battery Coolant

Circulates around the battery cell to assist in maintaining optimum battery temperature.
Temperature Sensors
Pressure Sensors
Combined Pressure & Temperature Sensors
Ultrasonic Level Sensors

 Coolant Breach/Water Intrusion Sensors

car diagram

● Temperature Sensors

Measure and monitor surface temperature of the many batteries within the battery cell, which is critical to preserving the chemistry of the battery.
• Single point temperature sensors
• Rigid and flexible types
• Custom sensor packaging

Thermometrics Logo

● Temperature Sensors

Measure and monitor battery temperature to detect Thermal Runaway conditions.
• Capable of single or multiple cell detection

● Pressure Sensors

Detect pressure change inside the battery cell that indicates Thermal Runaway conditions.
• Surface mountable
• Simple 3-command I2C interface
• Very low current consumption: <35μA

● Gas Detection Sensors

Detect the out-gassing of Carbon Dioxide (CO 2) to indicate pre-combustion conditions.
• Single and dual channel configurations
• Self-calibration with patented ABC Logic™ Software

● Gas Detection Sensors

Detect the presence of combustible gases that indicate Thermal Runaway conditions.
• Sensitive to multiple gases: H
2 / CH 4 / CO 2
• Fast response time: <10 seconds• IP6K7 rating

Thermometrics Logo
NovaSensor logo
Telaire Logo
SGX sensortech logo

● Temperature Sensors

Provide temperature and voltage sensing to monitor the state of charge of the battery cells.
• High current circuit for battery cell connectivity
• Available styles: Wire Harness and Flexible Printed Circuit (FPC)

Thermometrics Logo

● Temperature Sensors

Measure and monitor operating temperature of the power inverter to provide feedback on unsafe conditions.
• Fast response time
• Pigtail connector

● Inductive Position Sensors

Provide data on the angular position of the rotating motor shaft to optimize control of the motor inverter.
• Inductive eddy-current with weight and size reduction
• Stable output over extended temperature range (-40ºC/+160ºC) and radial/axial misalignment
• Robust against magnetic flux and external stray fields

Thermometrics Logo
Piher sensing systems logo

● Temperature Sensors

Detect over-temperature conditions during charging.
• Installed within the connector

Thermometrics Logo

● Temperature Sensors

Measure and monitor temperature of the motor coil to provide feedback on the operating conditions of the electric motor.
• Field-proven design
• Variety of lead lengths, terminal and connector options

Thermometrics Logo

● Temperature Sensors

Measure and monitor fluid temperature of inlet/outlet battery coolant to provide indication of battery cell temperature.
• No leak path – Sensor cavity and tube are one piece
• USCAR sealed connection system
• Many part geometries: inline tube, flying lead and integral sensor

● Pressure Sensors

Measure the pressure in the cooling system to control pump capacity.
• Internal metal sealing for high media compatibility and no leakage
• Customized calibration for high accuracy

Combined Pressure & Temperature Sensors

Measure pressure in the cooling system, while, at the same time, measure temperature of the coolant for optimum thermal management.
• Available versions: R1234yf (up to 35bar) and R744 (up to 200bar)
• Tested LIN 2.1 conformity
• Automatic address assignment within LIN network (Slave Node Position Detection)

● Ultrasonic Level & Temperature Sensors

Continuously monitor fluid level for early detection of coolant leakage.
• Level accuracy: ±2mm
• Temperature accuracy: ±2.5°C
• Output protocol offerings: Analog, PWM, SENT, CAN, LIN
• Input voltage options: 5V / 12V / 48V

● Coolant Breach/Water Intrusion Sensors

Detect the presence of coolant/water in the battery pack.

• Operates based on conductivity of the fluid being sensed

• Easy to install

• RoHS Compliant

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Major Markets Served

 Thermometrics, Inc.
Gas & Moisture
Moisture Meters
Thermal Validation
SGX Sensortech
Piher Sensing Systems
Wilcoxon Sensing Technologies
Piezo Technologies
Pressure & Temperature
All Sensors
Ultra Low Pressure
SSI Technologies
Level, Quality, & Pressure
Exa Thermometrics
EndevcoPCB Piezotronics
Aerospace (Commercial)
Airframe & Avionics
Fuel Systems
In-Cabin & Galley
Wind Tunnel Testing
Flight and Ground Testing
Air Quality (Indoor)
Air Handling Unit
Air Quality Monitoring
Clean Rooms
Filter Monitoring
Room Monitoring
Safety (Personal & Industrial)
Cabin Comfort
Engine Management
Fuel Handling System
Safety Systems
Construction & Restoration
Electrification EV/HEV
Battery Coolant
Battery Pack
Cell Connection System (CCS)
Charger Connector
Motor Coil
Power Inverter/E-Motor
Thermal Runaway
Environmental Monitoring
Air Handling Unit
Boiler Control
Building Pressurization
Chiller Control
Duct Measurement
Filter Monitoring
Outdoor Air
Room Monitoring
Water Management
HVAC - Medical Facilities
Climate Control Systems
Differential Pressure Measurement
Equipment Conditions
Floor Heating
Fresh Air Ventilation Control
HMI Controls
Hospital Beds & Wheelchairs
Humidity Control
HVAC Refrigerant
HVAC Systems
Inline Oxygen Measurement
Medical Equipment
Heavy Equipment & Off-Road (HVOR)
Cabin Comfort
Engine Management
Fuel Handling System
Safety Systems
Critical Care
Medical Instrumentation
Patient Monitoring
Respiratory Care
Surgical Assemblies
Ground Vehicles
Military Aircraft
Missiles / Munitions / Torpedoes
Soldier-Worn Systems
Non-Destructive Testing (NDT)
Oil & Gas
Pharmaceutical & Biotech
Process Control
Process Air
Process Equipment
Process Fluids
Process Gases
Process Automation
Thermal Validation