Power disconnect solution enables faster and safer DC fast charging

Sensata Technologies has released its new power disconnect solution to enable faster and safer DC fast charging. Its' unique solution consolidates contactors and GigaFuses from its leading Gigavac product brand to offer customers a value-added contactor module, simplifying their installations while producing safer and more effective system protection than conventional contactor and thermal fuse pairings.

To contend with traditional internal combustion engines, EVs require faster charging times, so EV charging systems are quickly migrating from 400V to 1,000V and from 50kW to up to 350kW to speed charging times to less than 20 minutes. While higher voltage and current levels lessen charging times, they raise the safety risks and design challenges for the systems. High voltage contactors offer safe circuit continuity while fuses are needed in tandem for circuit-protection in a hazardous short circuit event.

The increases in voltage and current levels not only need contactors with higher breaking abilities but also make the contactor and fuse pairings more technically challenging. To meet these challenges, DC fast charging infrastructure OEMs are exploring safer, higher-performing and more comprehensive solutions that develop on the traditional contactor and thermal fuse pairing.

Nick Moelders, vice president, Electrification at Sensata Technologies, explains: “Our recent wins with major Charging Infrastructure OEMs demonstrate the additional value we provide to our customers as we move from being a component supplier to a leading electrification solutions provider. Working engineer-to-engineer with the most innovative companies allows us to learn and adapt to the needs of the rapidly transforming clean energy market.”