TMB Highvolt

TMB – Temperature measurement in battery systems

Temperaturmessung im Hochvoltubereich

High-performance batteries in the field of e-mobility must meet high requirements. Short charging times with high currents, as well as large capacities for long ranges during vehicle operation and the supply of other e-mobility components push battery systems and other components to their limits. The largest part of the energy supply is converted into heat, which must be controlled, regulated and recorded. In the field of the development of modern battery systems and the associated high operating voltages, special measuring systems are used which have to meet the special safety requirements.

Rössel-Messtechnik offers ready-to-connect sensor cables for temperature measurement on high-voltage e-mobility components. Our high-voltage cables, tested by TÜV-Süd, can be connected directly to high-voltage modules, e.g. from CSM, and thus offer user-friendly sensor technology for measurements inside and outside battery components.

The specially developed HV cables are touch-proof and robust. The orange outer sheath made of PUR material identifies the cables as an application product for the high-voltage range in vehicle electrical systems. Their small diameter makes them ideal for space-saving applications. Since cables are often exposed to abrasion on body parts, the HV cables have a blue intermediate sheath. If the blue intermediate sheath becomes visible, this indicates that the cables are no longer reliable. The special, coded and fully insulated connector offers additional protection against accidental contact, even if the cables are not connected to measuring modules.


E-vehicles have a completely different powertrain design than their combustion engine counterparts. Battery and electric motor are the main components, but I also play a decisive role in components such as power electronics, alternator, cooling and, if necessary, transmission. Currently, almost lithium-ion batteries are used in electric cars. They convince with their long life cycle and high energy density. Thousands of lithium-ion cells are bundled in one battery block.


The electric motor as the driving element plays a central role, whereby the term electric motor is not entirely correct, since an electric motor can also be used as a generator and is also used accordingly during recuperation.


The power electronics control the voltage changes during driving and charging. The electronics convert the electrical energy into the voltage level and form required by the consumer. The central point is the high-voltage vehicle electrical system, via which all components are connected to each other.


High-voltage thermocouple cable type 4-CH-HV-KN-K

General product features
Operating temperature -40 to 150 C
Dielectric strength 3,7 kV AC to 6 kV DC
Operating temperature -40°C to +150°C (3000h)
Minimum bending radius 12 x cable diameter
Dielectric strength min. 3,7 kV AC up to max. 6 kV OC
Inner sheath FEP
Outer sheath Polyurethan (PUR)
Version ISO measuring tips insulated with shrink tubing

Schematic representation

1 Lemo plug 8-pin
2 Cover plate
3 High-voltage cable 4-CH-HV-KN-K
4 Shrink tubing black
5 Heat shrink tubing red
6 Heat shrink tubing yellow
7 Heat shrink tubing blue
8 Heat shrink tubing green
9 Schrumpfschlauch transparent
10 Outer jacket ø 4.5 mm
11 thermocouples type K 2 x 0.2 mm
12 Kapton cable 0.7 x 1.1 mm
13 FEP insulation 0.4 mm thick
14 3 x colour fibre
15 HV-TC marking