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Boost your e‑motor

Sensor solutions for thermal management, pressure sensing and position detection

In electric vehicles, especially the temperature, the pressure and the position of the rotor must be monitored at various positions along the drivetrain of an xEV to maximize performance and safety. This poses new challenges for the automotive industry.

Check out TDK’s extensive portfolio of special temperature, pressure and position sensor solutions for demanding e‑mobility applications.

Busbar

Monitoring temperature directly on busbars prevents load peaks, which would reduce the e-motor’s output performance and its lifetime. Therefore, temperature sensors are required, which can withstand high voltages measuring the temperature on hotspots whilst meeting harsh vibration and media requirements.

Ring terminal surface T sensor

The ring terminal sensor can be mounted anywhere where a screw can be inserted. By this screw, permanent contact with the surface is ensured and thus the measurement is accurate at all times. Copper as contact material offers good thermal coupling and perfect material compatibility with the copper busbar to prevent contact corrosion.

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Features

Temperature range -40 to +150 °C, short-term up to +200 °C
2.5 kV (DC) for 60 s or 5 kV (DC) for 60 s (overmolded variant)
Twisted wire for EMC
Flexible customizable wire lengths, R/T characteristics and connectors available on request
M4 or M6 eyelet made from copper alloy for mounting purposes

Clip-on surface T sensor (rectangular)

The sensor was developed for direct temperature measurement on busbars of xEVs. Because of the flexible clip-on mounting feature, it is easy to install and secure against vibration. The clip itself can be easily customized according to the customer application.

Features

Temperature range -40 to +180 °C, up to +200 °C / 100 h
Dielectric strength of 5 kV (DC) for 60 s
Fast response time <7 s for τ (63%)
Accurate busbar temperature readings
ATF oil resistance

High-voltage connector

There are multiple connections within xEVs via HV connectors e.g., battery to inverter. The temperature of these connectors themselves must be monitored to prevent overheating and to protect the surrounding plastic material. Therefore, such kinds of sensor systems must withstand voltages up to 5 kV.

Plug-in T sensor

TDK developed a high-voltage-resistant plug-in T sensor for DC connector pins. It is equipped with a ceramic sleeve. Consequently, the thermal conductivity is 200 times higher than with plastic, so that the response time is fast, and the dielectric strength is high.

Features

Operating temperature range from -40 to +150 °C, short-term up to +180 °C
High dielectric strength of up to 5 kV (DC)
Fast response time <10 s for τ (63%)
Easy integration due to the flexible addition of mounting features, in the shape of screw or clip solutions.

Cooling pipes

The temperature of the coolant can be used to determine the operating state of the battery, e-motor, or HVAC refrigerant system. To avoid leakage, measuring the temperature outside the pipe is a simple solution that can be integrated quickly.

Clip-on surface T sensor

Measuring the temperature of fluids is exactly what TDK's clip-on surface temperature sensors for pipe mounting offer, with no additional sealing system. Moreover, it can be easily mounted on a pipe surface without tools.

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Features

Customizable solutions for different pipe geometries and electrical parameters
Fast response time <5 s for τ (63%)
Excellent thermal connectivity due to clip design
Secure and resistant to vibrations
simple and quick

Cooling circuits

Within thermal management, different fluid streams interact thermally with each other. Especially before and after heat exchangers, sensors are needed to monitor different temperatures for fluids like water-glycol and oil. Therefore, it is important to equip the different immersion fluid sensors with sealing systems that can withstand different pressure levels according to the application.

Immersion T sensor

To monitor the temperature of fluid circuits, e.g., of ATF oil, or coolant in electric vehicles, an immersion temperature sensor is commonly used. The product images show examples of fully sealed systems being exposed to a liquid flow. There are various mounting features available, using screw, thread, or clever clip solutions.

Features

Very fast response time <3 s for τ (63%)
High temperature resistance up to +150 °C
Fully sealed system for immersion applications
Designed for 10 bar fluid pressure
Cable-bounded solutions available

Rotor position (resolver replacement)

Electric traction motors need accurate rotor position detection at high rotation speeds up to 150,000 rpm to maximize torque and increase efficiency which is essential for xEVs to maximize range.

On-axis rotor position sensing

TDK offers rotor position detection solutions using tunnel magnetoresistance (TMR) or Hall-effect sensors at the shaft end. Analog TMR sensors offer high resolution and minimal angular deviation for precision, while TMR sensors with digital output save space, ideal for designs without PCB. Hall effect-based sensors are extremely robust against magnetic stray fields and mechanical variations and meet a wide range of customer requirements.

Analog TMR sensors

A TMR sensor can detect the angle using a simple magnet placed at the end of the shaft with the sensor placed on the front. This configuration works independently of the number of poles of the e-motor and therefore does not require complex hardware changes.

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Features

High reliability and low FIT rates for safety-critical applications
Fast response and stable position measurement over temperature and lifetime
Supports ASIL B(D) by TAS414x (system level ASIL D)
Very high output differential voltages allow direct connection to ADCs
Temperature range -40 to +150 °C
Very small single-mold packages available

TMR analog front-end IC ASA 2310

For setups with remote sensor modules and long wire harnesses, the ASA 2310 TMR analog front-end IC facilitates the use of analog TMR sensors. It features a powerful output buffer, integrated protection circuitry against ESD and EMI as well as internal signal conditioning with on-chip calibration. The integrated safety monitoring reduces the workload for the external ECU.

More at TDK-Micronas

Features

Optimized signal conditioning for TMR signals, support of various TDK TMR sensors
ASIL B ready SEooC acc. to ISO 26262:2018 (Metrics (PMHF, SPFM, LFM) according to ASIL C)
Suitable for applications with up to 650,000 rpm
Operates from TJ = -40 °C up to +150 °C
Small 3 × 3 mm² DFN12 SMD package

Digital TMR sensors (PCB less)

TDK offers TMR sensors as a system-in-package for PCB-less applications, incorporating TMR bridges, a signal conditioning IC, and passive components. This innovative solution can be welded or soldered directly onto package leads, connectors, or terminals, eliminating the need for a PCB. This reduces system size and cost.

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Features

Fast response, high angular accuracy, and advanced compensation algorithms
Compliant to ISO 26262:2011 supports ASIL B on system level
No PCB and no external components required
Lowest deviation of angle error of just ±0.05°

Fast 2D Hall-effect sensors

The HAL 3021, a high-speed angular sensor based on Hall-effect technology, suppresses external magnetic stray fields with its Hall-plate array. It efficiently measures absolute angular position with a simple two-pole magnet at the end of the shaft. It is robust against mechanical errors like off-axis displacement and tilt while compensating for irregularities such as amplitude deviation and offset errors at both sensor and system levels.

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Features

High-speed 360° contactless angle measurement
Intrinsic robustness against DC and AC magnetic stray fields (ISO 11452-8)
ASIL C ready according to ISO 26262:2018: ASIL D on system level
Various integrated diagnostic mechanisms ensure correct operation and simplify external safety monitoring
Programmable magnetic-field range between 5 and 250 mT

Off-axis rotor position sensing

For detecting the rotor position in an off-axis position, TDK offers analog TMR sensor solutions as a single chip solution or as a combined chipset including a dedicated front-end IC for optimized signal conditioning. The remarkably compact size of this chipset makes it easy to integrate it into the design, for example as a versatile replacement for traditional resolvers.

Analog TMR sensors

Analog TMR sensors from the TAS family provide high resolution and low angular error for rotor position sensing in both on-axis and off-axis configurations. In the off-axis setup, sensors can be placed near the shaft, offering flexibility in sensor and magnet placement along the shaft, making integration into existing system designs easier.

More at TDK Product Center

Features

Fast response and very stable position measurement (over temperature and lifetime)
Scalable sensor setup allows stray-field robust position measurements
Supports ASIL B with single TMR and ASIL D with multiple TMR sensors (system level ASIL D)
Temperature range -40 to +150 °C
Small DFN4 SMD package

TMR analog front-end IC ASA 2310

By combining TDK's TMR TAS sensor family with the ASA 2310 TMR analog front-end IC, users can cost-effectively scale their setups based on accuracy, EMC, or safety requirements. The ASA 2310 supports up to four TMR half-bridge sensors simultaneously, enabling various system architectures with robust stray-field and fail-safe concepts.

More at TDK-Micronas

Features

Optimized signal conditioning for TMR signals, support of various TDK TMR sensors
ASIL B-ready Safety Element out of Context (SEooC) acc. to ISO 26262:2018 (Metrics (PMHF, SPFM, LFM) according to ASIL C)
Suitable for applications with up to 650,000 rpm
Temperature range -40 up to +150 °C
Small 3 x 3 mm DFN12 SMD package

Further products

New products will be introduced soon. For more information, please contact TDK-Micronas.

Park lock

xEVs drive the trend towards an electric axle with the need for a park lock actuator. Ideally, this actuator is directly integrated into the electric axle drives. The safe locking can be checked by using a 2D position sensor. Additionally, xEVs drive the need for stray-field robustness. Furthermore, an ISO 26262-compliant device is mandatory.

3D Hall-effect sensors

This high-resolution sensor is part of a new generation of TDK’s 3D position sensors addressing the need for stray-field robust 2D position sensors (linear and angular) as well as the ISO 26262-compliant development.

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Features

Accurate angular measurement up to 360° and linear position detection
3D position detection supporting transmission of two angles out of BX, BY, BZ
Compensation of magnetic stray fields SEooC ASIL B-ready according to ISO 26262 to support functional safety applications
Customer-configurable PWM or SENT output (push-pull output & open-drain output)

Clutch/gear position

Multi-speed transmission in xEVs boosts range and performance. A gear position sensor inside the automatic transmission communicates with the vehicle's electrical system, utilizing 3D sensors (PWM, SENT, or SPI output) with linearization setpoints for travel distance. Functional safety demands digital output formats like SENT and compliance with ISO 26262.

HAL 3900 and HAL 3930

These high-resolution sensors are members of TDK’s new 3D position sensor generation addressing the need for stray-field robust 2D position sensing (linear and angular) as well as the ISO 26262-compliant development.

More at TDK Product Center

Features

Accurate angular measurement up to 360° and linear position detection
3D position detection supporting transmission of two angles
Compensation of magnetic stray-fields
SEooC ASIL B-ready according to ISO 26262 for functional safety
Customer-configurable PWM or SENT output (HAL 3930), or SPI interface (HAL 3900)

Windings / hairpins

Particularly in the field of e-mobility, compact designs are always extremely important. This is mainly due to limited space in a passenger car. This requires compact solutions that can be integrated easily. Therefore, multiple mounting features are available from TDK to ensure a smart and simple assembly.

Surface T sensor - NTC RP series

The NTC RP series is suitable for monitoring the temperature in the windings or hairpins of electric motors.
Therefore, the sensor is protected by a special insulation system against high voltage applications like hairpins. Additionally, the sensor can withstand different media e.g. oil.

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Features

Excellent resistance against automatic transmission fluid
Temperature range -40 to +200 °C
Fast heat response of 3.3 s for τ (63%) in oil due to its small size
Compact design
High voltage strength 2 kV AC

Clip-on surface T sensor (rectangular)

Features

Temperature range -40 to +180 °C, up to +200 °C / 100 h
Dielectric strength of 5 kV (DC) for 60 s
Fast response time <7 s for τ (63%)
Accurate busbar temperature readings
ATF oil resistance

Inverter

An inverter is a device that transforms the energy stored in the battery, from direct current (DC) into alternating current (AC) in a structured and controlled way. Due to high current flow any overheating process has to be avoided. Therefore, corresponding hot spots need to be monitored directly by small NTC chips or indirectly on busbars close to high voltage components.

L860 leadless NTC chip

The L860 series of wafer-based NTC chip thermistors represents an ideal solution to monitor the temperature reliably and precisely as well as to reduce manufacturing costs. The electrical contacting pads are located on the top and bottom surfaces of the chip, with the bottom side for soldering or sintering and the top side for bonding.

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Features

Narrow tolerance of about ±2.0 K at 120 °C
Asymmetric thin film terminations
- Bottom: silver soldering / silver sintering
- Top: gold for Al heavy wire bonding
Silver thick film terminations
- Designed for double sided silver sintering

Clip-on surface T sensor (rectangular)

Features

Temperature range -40 to +180 °C, up to +200 °C / 100 h
Dielectric strength of 5 kV (DC) for 60 s
Fast response time <7 s for τ (63%)
Accurate busbar temperature readings
ATF oil resistance

Ring terminal surface T sensor

More at TDK Product Center

Features

Temperature range -40 to +150 °C, short-term up to +200 °C
2.5 kV (DC) for 60 s or 5 kV (DC) for 60 s (overmolded variant)
Twisted wire for EMC
Flexible customizable wire lengths, R/T characteristics and connectors available on request
M4 or M6 eyelet made from copper alloy for mounting purposes

Get whitepaper

Read our whitepaper to learn how TDK's sensor solutions can help you tackle your e-motor application design challenges.

This whitepaper examines various temperature and positioning techniques and illustrates why the TDK solutions are superior and help to combine long driving range, convenient agility, and safety in xEVs.

Get whitepaper

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