High-voltage sensors up to 6 kV DC are designed to take measurements in battery systems and high-voltage components found in electric vehicles

A customer required a touch-safe temperature measurement solution designed to handle temperatures ranging from -60°C to +300°C at a maximum ambient temperature of 150°C, which can be flexibly installed and used in vehicles while also ensuring touch protection according to VDE. It also needed to comply with the guidelines of DIN EN 61010 for connecting to standard measuring devices. Touch protection also needed to be ensured from the sensor cable via the external insulation to the connection plug and documented with a high-voltage test. We were required to guarantee traceability with the serial number documented in a test report. The measuring system also needed to be certified by a TÜV laboratory.

Over a period spanning roughly two years, we developed the individual components and test procedures for the prototypes in partnership with the customer. The sensor cable needed to be designed and built with different insulation layers in a novel combination. We provided our own development environment to develop this sensor, supplying both the staff and technology, and were able to successfully obtain certification from the TÜV laboratory along with approval from the automotive company at the end of the development period. By developing the prototypes, we subsequently created an entire product line, which has now been fully accepted and is used in the entire automotive industry to produce electrically powered vehicles. Each sensor is individually tested and sealed on our high-voltage test bench and stored in welded packaging. Only once this is complete are the finished sensors packaged in cardboard boxes. This approach ensures that the products meet the strict safety standards of the automotive industry.

Our high-voltage cables approved by TÜV-SÜD in accordance with DIN EN 61010 can be directly connected to standard high-voltage measurement modules, offering user-friendly sensors for taking measurements within and outside battery components. This makes it possible for customers to measure temperatures on high-voltage components without touch voltage. Thanks to the safe insulation and connection technology, the engineers and test bench staff are protected from high voltage in their workplace and can safely conduct their measurement tasks. Our high-voltage sensors are now used by all automotive manufacturers and development companies involved in e-mobility and battery system development.