E-Mobility & Fuel Cell

Electromobility (E-Mobility) & Fuel Cell Electromobility (FCE-Mobility)

Increasingly, vehicles are being built on electric motors instead of internal combustion engines and smart components are increasingly being added into vehicles. The switch to e-mobility presents the automotive industry with major challenges, as an electric vehicle requires additional sensors that measure and control in the harsh vehicle environment.

Automakers and their suppliers are developing new knowledge and know-how. New components such as electric batteries, electric motors, and the related powertrain, are being produced and assembled with a high degree of automation. Also, a rise in varieties of components in the vehicle leads to components and parts that must be reliably detected, checked, and identified with sensors. For example, new compact, lightweight and powerful electric motors and controllers enable vehicle hybridization and electrification – especially when there is limited powertrain space

Sensor Solutions

IST puts you in the driver’s seat by providing a complete ecosystem of sensors and technologies that provide high reliability in harsh environments to keep your design on track.  IST has developed a number of specialized temperature, humidity, conductivity and flow  sensor solutions enabling the electrification of e-transportation. We offer a wide range of sensor elements, modules and assemblies to ensure maximum accuracy, durability, and reliability.

Whether you’re creating an application to make the e-mobility experience more cost-effective, developing a product to electrify the motor, or designing a new electric industrial vehicle, we are ready to help you navigate from start to finish. The business strategy of IST AG is to provide engineered sensor component and design in solutions, providing dependable values through profound material science know-how and intelligent factory calibration together with state-of-the-art manufacturing methods and consistent quality. IST AG is today, a one-stop shop for temperature, humidity, flow, and conductivity components, and an ideal partner to launch new quality products.

Energy management in Electric Motors

Lighter and more energy-efficient e-mobile products are driving a new generation of electric motors and generators. Today, axial flux technology has resulted in motor technology that delivers 3 to 5 times more power density compared with traditional EV motors. Traditional Permanent Magnet EV Motors suffer from losses due to the large amount of iron in the motors. Compared with Traditional Permanent Magnet EV Motors, axial flux motors come with 80% less iron cores losses and over 5 times less iron mass, replaced by copper windings, and delivering up to 24% more vehicle range.

New high-speed axial flux motors deliver peak power densities in excess of 15 kW/kg and require smart energy management of the motor by cooling the windings for the lowest possible stator temperatures. Consequently, a highly accurate temperature measurement of the copper windings is required.

Highly reliable, customized platinum thin film RTD temperature sensor installed in a stator connection module ensures accurate measurement of temperature according to the IEC 60751 norm, in the windings of the electric motor.

The IST platinum thin film RTD temperature sensors are developed with the highest quality materials and cover a wide operating temperature range. The sensors can operate in the harshest conditions while experiencing minimal drift. The construction is extremely robust and due to the small dimensions, the sensors are offered in various housings. The platinum temperature sensors are available with a standard TCR of 3850 ppm/K and with accuracies according to the IEC 60751 norm.

IST also offers custom RTD platinum sensors fitted to application-specific requirements in terms of specified TCR values, nominal resistance, dimensions, housings and lead wires amongst other variations.

> Click here for more information

Consult with our engineering team for a profound technical discussion about an optimized Temperature sensor for your electric motor application

Electric Battery Modules

Greater fuel cell security, increased performance and longer operating life are driving electric battery development.  Inaccuracies in traditional measurement of battery temperatures result in wide margins reducing the driving range due to engine performance inefficiencies. Water and coolant intrusion into the battery enclosure can increase the risk of battery pack failure and possible electrocution.

Precision Platinum thin film sensors are ideal for the temperature monitoring of the coolant liquid in a low-temperature fuel cell, while a leak detection humidity sensor can detect coolant leakage or water ingress via a change in moisture content.

Platinum thin film sensors measure in harsh conditions with extremely high stability and low drift, maximizing the efficiency and lifetime of the electric battery. The IST platinum thin film RTD temperature sensors are developed with the highest quality materials and cover a wide operating temperature range. The sensors can operate in the harshest conditions while experiencing minimal drift. The construction is extremely robust and due to the small dimensions, the sensors are offered in various housings. The platinum temperature sensors are available with a standard TCR of 3850 ppm/K and with accuracies according to the IEC 60751 norm.

IST also offers custom RTD platinum sensors fitted to application-specific requirements in terms of specified TCR values, nominal resistance, dimensions, housings and lead wires amongst other variations.

Customized adaptations are available on request.

> Click here for more information

Consult with our engineering team for a profound technical discussion about a Platinum thin film temperature sensor for your electric battery  application.

Sensors for Coolant Leakage

The IST AG MK33-W capacitive rH humidity sensor has been developed especially for high-end measuring applications and extreme environments making it optimal for coolant leakage applications. The MK33-W excels through its extremely high humidity and temperature working range and its outstanding chemical resistance suits the harsh electric battery environment

> Click here for more information

Customized adaptations are available on request.
 

Electric Power Trains

Electric power trains are becoming lighter and smaller, demanding robust designs and reduced energy consumption that extend vehicle range. For maximum powertrain efficiency, operating at or close to the load limits of the power IC is required. For power train efficiency, long-term stability and reliability, precision temperature measurement needs to be made with innovative assembly and connection methods operating up to 300 °C.

A Platinum thin film sensor mounted in a flat probe head for optimum temperature transfer from flat surfaces ensures accurate measurement of temperature according to the IEC 60751 norm, in the electronic power module. 

The IST platinum thin film RTD temperature sensors are developed with the highest quality materials and cover a wide operating temperature range. The sensors can operate in the harshest conditions while experiencing minimal drift. The construction is extremely robust and due to the small dimensions, the sensors are offered in various housings. The platinum temperature sensors are available with a standard TCR of 3850 ppm/K and with accuracies according to the IEC 60751 norm.

IST also offers custom RTD platinum sensors fitted to application-specific requirements in terms of specified TCR values, nominal resistance, dimensions, housings and lead wires amongst other variations.

Customized adaptations are available on request.

> Click here for more information

Consult with our engineering team for a profound technical discussion about an optimized temperature sensor element for your application.

Charging Plug

Demanding electric safety requirements are driving new progressive charging plug designs and performance improvements. Charging plugs must endure a service life >10 years with no deterioration in charging efficiency. This demands precise, stable and drift-free temperature measurements throughout the service life, with fast response to a sudden temperature spike indicative of plug failure.

For optimal charging time, efficiency and safety, long-term stability and reliability, precision temperature measurement is required with innovative assembly and connection technologies inside the plug.

Platinum thin film sensors measure in harsh conditions with extremely high stability and low drift, maximizing the efficiency and lifetime of the charging plug. The IST platinum thin film RTD temperature sensors are developed with the highest quality materials and cover a wide operating temperature range. The sensors can operate in the harshest conditions while experiencing minimal drift. The construction is extremely robust and due to the small dimensions, the sensors are offered in various housings. The platinum temperature sensors are available with a standard TCR of 3850 ppm/K and with accuracies according to the IEC 60751 norm.

IST also offers custom RTD platinum sensors fitted to application-specific requirements in terms of specified TCR values, nominal resistance, dimensions, housings and lead wires amongst other variations.

Customized adaptations are available on request

> Click here for more information

Fuel Cells - Coolant

Fuel cell vehicles (FCV) require special coolants for fuel cells to support the current advancements in fuel cell technologies. These new coolants provide protection against corrosion, overheating and frost and they can be used safely with ion exchange resins in the fuel cell cooling system.

Compared to non-inhibited glycol water mixtures, these coolants can continually maintain a low electrical conductivity, and by doing so, secure the electrical safety of the system and reduction in loss of energy. Continuous conductivity measurement enables the quality of the coolant to be monitored quickly and reliably

Measurements are made with conductivity sensors that work on the two-electrode method. [Inter-digital planar electrode and Pt1000 Temp Sensor]. The cell constant of a measuring cell must be certified by its manufacturer. IST AG has many years of experience in measuring cells in manufacturing that meet the most stringent requirements. IST AG offers the conductivity measuring cell Transmitter in a housing containing the electronics based on our conductivity sensors.

Customized adaptations are available on request.

> Click here for more information

Consult with our engineering team for a profound technical discussion about a conductivity measuring cell Transmitter for your Fuel Cell application.

Fuel Cells - CGH2 Compressed Gaseous Hydrogen

Fuel cells operate at higher efficiencies than combustion engines, and, can convert the chemical energy in the fuel to electrical energy with efficiencies of up to 60%. Fuel cells have lower emissions than combustion engines. Hydrogen fuel cells emit only water, so there are no carbon dioxide emissions and no air pollutants at the point of operation. Also, fuel cells are quieter during operation as they have fewer moving parts.

Fuel cells operate like batteries, but they do not run down or need recharging. They produce electricity and heat, as long, as fuel is supplied. As a fuel, CGH2 Compressed (and extended-compressed) Gaseous Hydrogen requires extremely cold storage temperatures which have to be closely monitored, as the highest possible storage pressure at cryogenic conditions (subsequent to refueling) is 350 Bar with temperature levels of below 100 Kelvin

Owing to the special construction of a ZrO2 Substrate with a Coefficient of thermal expansion matched to platinum and stable characteristics curve, the IST AG Platinum RTD temperature sensor “PW series” is ideal for low temperature measurement down to -200 °C. The benefits being no stress generated in the platinum layer and reduced hysteresis.

Customized adaptations are available on request.

> Click here for more information

Consult with our engineering team for a profound technical discussion about a temperature sensor for your Fuel Cell storage application.

 

LiDAR Devices

LiDAR Devices act as the eye of the self-driving autonomous vehicles. They provide a 360-degree bird’s eye view of the surrounding terrain to drive themselves safely.

IST AG provides solutions for thermal management of the LIiDAR Laser modules and Optical Components.

> More information may be found here