Sensata Technologies has introduced its STEV high-voltage contactor series, designed to support the electrical and safety requirements of electric vehicles (EVs) and plug-in hybrid electric vehicles (PHEVs).
The STEV series is intended for high-voltage switching applications where efficiency, durability, and protection are critical to overall vehicle performance.
High-voltage contactors are electromechanical switches that open and close power circuits repeatedly over a vehicle’s operating life. In EVs, they manage power flow between the battery and systems such as the inverter and onboard charger.
Their performance affects electrical safety, thermal behavior, and long-term system reliability, making them a core element of modern EV power architectures.
The STEV series is designed to scale across multiple vehicle segments, from plug-in hybrid passenger vehicles to battery electric pickup trucks and Class 8 commercial vehicles. This scalability allows OEMs to apply a common contactor platform across different programs, reducing integration effort and supporting platform standardization.
The contactors are configurable to meet specific vehicle and system requirements, using a common switching architecture developed for automotive applications. The STEV series is engineered to meet automotive quality and safety requirements, including Advanced Product Quality Planning (APQP) processes and OEM certification standards, supporting deployment across global vehicle platforms.
Sensata’s high-voltage contactor technology is already deployed in large-volume vehicle programs and continues to be adapted for new electrified architectures. The STEV series is designed to provide stable switching performance with low contact resistance and controlled heat generation. Hermetic sealing and modular construction support continuous current ratings from 150 to 600 A, along with short-circuit withstand capability exceeding 20 kA, enabling use in a range of BEV and PHEV systems.
Features:
- Single or dual assembly options: Configuration flexibility for different power distribution layouts and packaging constraints
- Bidirectional current capability: Select variants support non-polarity main contacts for advanced EV power system designs
- Hermetic ceramic sealing: Arc containment and environmental protection, with IP67 ingress protection available on specific models
- High electrical isolation: Coil-to-contact dielectric strength up to 3.0 kV and insulation resistance of 1000 MΩ at 1000 Vdc
Sensata supplies high-voltage components through a global network of engineering and manufacturing facilities across North America, Europe, and Asia. This regional footprint supports localized production, OEM supply-chain strategies, and in-region vehicle manufacturing programs.
The STEV series expands Sensata’s electrification portfolio, addressing the switching, safety, and integration needs of modern EV power systems.
Filed Under: High Voltage Systems (> 60 VDC), Power Electronics, Technology News