eVehicle Technology
acoustic vehicle alerting system

New Coolant Leak Detection Sensor to Detect Water in Electric Vehicle

Coolant Leak Detection Sensor

Amphenol Advanced Sensors now offer their coolant leak detection sensor for use in electric vehicles that are used to detect the presence of water.

Amphenol Advanced Sensors who are known for pioneering technologies and embedded measurement solutions now offer their coolant leak detection sensor for use in electric vehicles that are used to detect the presence of water and coolant in the vehicle’s battery pack enclosure. The leak detection sensor can detect the smallest amount of water or coolant in the Battery Management System (BMS) and will alert the operator to take appropriate action to reduce risk of the battery pack failing or possible electrocution.

Water Leak Detection Sensor

Recent widespread implementation of large format battery-powered industrial equipment, stationary power, and road vehicles has presented some unique engineering challenges in onboard diagnostics (OBD) and fault detection for long-term, low maintenance battery systems. One of the most significant challenges is to ensure the safety and reliability of these power management systems is the presence of water.

Recent widespread implementation of large format battery-powered industrial equipment, stationary power, and road vehicles has presented some unique engineering challenges in onboard diagnostics (OBD) and fault detection for long-term, low maintenance battery systems. One of the most significant challenges is to ensure the safety and reliability of these power management systems is the presence of water.

While substantial design measures are taken to prevent water intrusion into the battery enclosure, there are still instances where this can occur. In stationary power systems, exposure to rain and standing water from flooding is not only a short-term concern, but also contributes to corrosion or leakage of the enclosure, exposing the battery system to water. In mobile applications, the pack shell can be damaged from debris penetrating the shell and from the long-term effects of corrosion. Seams and joints in the enclosure can also open because of twisting or vibration. Additionally, many large format battery pack enclosures utilize cold plate cooling systems, which can develop leaks over long duration use. Temperature and barometric pressure variations within the air space of an enclosure may also allow condensation to form.

By applying its extensive knowledge and capabilities in automotive sensing applications, Amphenol Advanced Sensors employed its Thermometrics, Inc. brand to design the Coolant Leak Detection Sensor as a cost-effective solution to address the safety and reliability concerns associated with the presence of water/coolant in battery packs. The sensor operates on standard 5V power and can detect as little as 2.8mm of standing water in the bottom of the battery pack enclosure. For diagnostics, the sensor includes a 510kΩ resistor in parallel with two plated contacts for open/short circuit detection. Its small footprint allows for various mounting positions, along with custom length wire leads and connector options. The Coolant Leak Detection Sensor is validated against aggressive automotive standards and includes 2D barcode for full traceability requirements.

Assembly of Water Leak Detection Sensor in Electric Vehicle (EV) Battery Packs

Amphenol Advanced Sensors, with its portfolio of industry-leading brands – Thermometrics, NovaSensor, Telaire, Protimeter and Kaye – is an innovator in advanced sensing technologies and embedded measurement solutions customized for regulatory and industry-driven applications across the automotive, medical and industrial markets. Amphenol Advanced Sensors creates value by providing critical information for real-time decisions.

Amphenol Advanced Sensors is part of Amphenol Corporation, based in Wallingford, CT.

Avatar photo

eVehicle Technology

Join thousands of eVehicle Experts and get the latest updates straight to your inbox!