Current Sensors
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Author: Quaid Rasheed Efficient sensing for motor current is critical to electric vehicles (BEVs, HEVs and PHEVs). Although current sensors are needed throughout an EV to enable a range of functions, the AC current sensor is key to controlling AC motors. The packaging of these single or multiphase sensors can cause roadblocks in a vehicle’s development process as there is limited space to mount them. Image to be added next revision We provide customized solutions to meet a wide range of performance needs based on our established modular design building blocks. CTS current sensors are accurate within ± 2.5% at 800-1500A, and solutions can be tailored to fit unique needs. Our AC current sensors provide a cost-effective solution for high-amperage AC drive motors, even with customized packaging and mounting options. Engineered per customer application design, the current range is scalable up to 1500A or more. Designed using Hall-effect technology, these sensors provide a consistent, high-performance signal in a light weight, streamlined solution. Regardless of your busbar arrangement or other housing requirements, our engineers can build a sensor to exact specifications, guaranteeing that it will fit your motor. APPLICATION CTS engineers collaborate with our customers to create unique solutions. One customer had a challenging request, a highly accurate current sensor that could operate at 1,000A while being able to fit in a very limited space. This customer had already designed a motor in a way that worked best for their vehicle, however, none of the off-the-shelf sensing solutions they explored would fit. Our engineering team worked hand in hand with the design engineers to create a customized casing to fit their application. This enabled the current sensor to be properly mounted and fastened with their busbar arrangement, including mounting tabs with screws, a snap-fit, and being soldered into the PCB. From concept development to high-volume production at one of our global manufacturing locations, CTS provides design and development support for your AC current sensor needs. The EV market continues to evolve, so as your current sensors evolve with it, CTS can partner with your team to create a unique solution. We have been a trusted supplier of automotive sensors to major OEMs for a wide range of safety and powertrain applications since the 1970’s, and first entered the EV space with the creation of our DC current sensors. With over 100 million automotive sensors in the field, we have the engineering expertise and production capabilities to support a wide array of applications. The graphic depicts the change in connector orientation and casing shape.

DESIGN PROCESS AUTOMOTIVE EXPERTISE CTS Corporation began expanding into the automotive market in the early 1970's, when the U.S. government first issued requirements for controlling automotive emissions. To meet the new demand for throttle positioning sensing and exhaust gas recirculation controls, we developed custom under-the-hood and chassis position sensors. Over the last forty years, CTS has grown into a variety of transportation markets, including commercial and off-road vehicles, heavy equipment, and motorcycles. Today, we are a leading provider of sensing solutions, smart...