Continental launches new sensors to guard EV batteries; present and influence

Continental launches new sensors to guard EV batteries; present and influence


Continental is launching two new sensors for electrified autos: the Present Sensor Module (CSM) and the Battery Affect Detection (BID) system. Each new options deal with defending the battery and/or on battery parameter retention.

The high-voltage Present Sensor Module (CSM), which can transfer into manufacturing this yr, measures the present and concurrently detects temperature. The Battery Affect Detection (BID) resolution is a lightweight different to heavy underfloor “armoring” in opposition to harm.

The high-voltage Present Sensor Module (CSM) gives the present and temperature info to maintain the battery protected and guarantee long-term sturdiness.

Contemplating that the battery is the only most costly element in an electrical automotive, the CSM was not simply developed to guard the battery from overcurrents, however it’s going to additionally assist to retain the battery parameters by limiting growing old results. Built-in both within the battery disconnect unit or within the battery itself, the CSM will present the 2 decisive bits of knowledge for battery safety in addition to dependable driving vary monitoring.

To help strict purposeful security necessities, the CSM is on the market as a two-channel sensor, measuring present independently by integrating shunt expertise and corridor expertise in a compact, single unit.

The BID together with a light-weight construction detects underfloor impacts and alerts the motive force if a cease at a storage is important in consequence. This relieves the motive force of the difficult resolution whether or not an influence at excessive pace or a low-speed floor contact could have broken the battery. Compared to present steel underfloor safety the BID resolution can save as much as 50% of weight.


The Present Sensor Module CSM totally helps ASIL D on system degree.

Lithium-Ion batteries retailer a large amount of vitality to offer a pretty driving vary. Notably throughout charging, excessive present flows into the battery. Owed to inevitable bodily results, charging (and discharging) a battery will warmth it up—particularly high-power quick charging or sporty driving. To forestall the automotive battery from overstress, the present must be managed to restrict the temperature gradient.

A lithium-ion battery has an optimum temperature span by which it is extremely protected and ages very slowly. Nevertheless, quick charging the battery is a tradeoff between holding the battery protected and wholesome and limiting the period of charging. That is finest performed on a precise knowledge foundation.

—Horst Gering, Program Supervisor within the Passive Security and Sensorics Section

The CSM additionally helps to calculate the exact remaining vary by monitoring present consumption.

The CSM measured present could be calibrated as much as 2,000 Amps with higher than ±1% accuracy on the shunt channel and ±3% accuracy on the corridor channel, plus temperature within the vary between -40 °C as much as 125 °C. Each present measurement applied sciences present full galvanic separation. This enter is then offered through CAN interface to the battery administration system.

Along with optimizing the effectivity of charging whereas defending the battery, the CSM will even assist to detect mechanical malfunctions, which might result in a fireplace if undetected. The CSM totally helps ASIL D on system degree.

The manufacturing of the CSM will start inside 2022 for a worldwide automaker’s state-of-the-art electrical car. The primary product is a part of a modular sensing platform which is scalable for added options resembling voltage measurement and variety of measurement channels.


The Battery Affect Detection operate can sense attainable battery harm and warn the motive force accordingly.

Battery Affect Detection. Usually, the lithium-ion battery of an electrical automotive is built-in in an underfloor place the place its weight contributes to a low middle of gravity and the place it’s effectively protected by the car construction—with two potential exceptions. At excessive speeds objects, resembling lashing straps, could be swirled up and harm the underfloor. At low speeds floor contact throughout a parking maneuver may trigger harm.

Subsequently, electrical autos are fitted with a big and sometimes heavy cowl to guard the battery compartment from the underside. Nevertheless, if an influence happens, it will likely be as much as the motive force to evaluate whether or not the automotive must be checked at a storage.

This isn’t a satisfying state of affairs as there may be poor visibility beneath a automotive, plus it takes a educated eye to evaluate the true harm.

—Johannes Clemm, Managing Director Continental Security Engineering Worldwide

To assist the state of affairs and make a light-weight underfloor safety possible, Continental has developed the pressure-sensor based mostly Battery Affect Detection resolution.

This method detects and classifies underfloor influence occasions to alert the motive force if the battery integrity could have been breached. This manner the automotive proprietor can take precaution earlier than a punctured battery might ignite at a later level. As well as, the BID identifies the realm of the harm, so the battery administration system can empty the cells in that space to forestall any danger of fireplace, Clemm provides.

The BID covers the 2 typical influence dangers: low-speed floor contact and high-speed intrusion.

Compared to present options the sensor-based underfloor safety can save as much as 50% of the load of present battery shielding resolution per car. The strain sensor satellites used within the BID derived from the confirmed Pedestrian Safety System (PPS pSAT) which has been in serial manufacturing and utilized in tens of millions of autos for greater than ten years. Any influence is detected through a ensuing strain sign in an air-filled silicone tube that’s built-in in serpentines on the backside of the battery compartment. The time distinction between the sign’s arrival on the two strain satellites at each ends of the tube makes it attainable to calculate the realm of the influence. The severity of the influence could be labeled through sign thresholds that serve to set off cascaded alarms to the motive force.


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September 2022