Sensata launches OmniNode power unit for commercial EVs
Sensata Technologies has introduced the OmniNode, a standardized high-voltage power distribution unit for battery-electric commercial trucks and buses.
Sensata Technologies has launched the OmniNode, a patent-pending, off-the-shelf high-voltage power distribution unit for battery-electric commercial vehicles. The company says the system consolidates DC charging, switching, circuit protection, sensing, diagnostics, and communications into a single package built from its own components.
The OmniNode is designed for on- and off-road commercial vehicles, including Class 5 and above trucks and buses. According to Sensata, this standardized unit reduces the industry's reliance on custom-engineered solutions. It aims to cut integration and validation work while simplifying sourcing for vehicle manufacturers. The company also states that one design can be reused across different vehicle programs and configurations.
Brian Wilkie, Sensata’s Executive Vice President and President of Aerospace, Defense and Commercial Equipment, commented on the launch. "With the OmniNode, we are delivering an integrated, off-the-shelf approach that helps engineers simplify power distribution architecture, accelerate development timelines and bring greater consistency and efficiency to vehicle platform design," he said.
Technical Specifications
The product's technical specifications are designed for demanding commercial applications. Sensata says the unit requires no active cooling, even in conditions with low airflow.
| Specification | Rating |
|---|---|
| Operating Voltage | Up to 1,000 V DC |
| Continuous Current | 500 A |
| Boost Current (15 min at 60° C) | 700 A |
| Ambient Temperature Range | -40° C to 85° C |
| Maximum Altitude | 4,000 m |
| Overcurrent Protection (at 850 V) | Up to 1,250 A |
| Short-Circuit Protection Range (at 850 V) | 1.25 kA to 40 kA |
| Dielectric Withstand (HV circuits) | 2.7 kV |
| Dielectric Withstand (HV to LV) | 4.3 kV |
Protection and Safety Features
The OmniNode includes several protection and safety systems. Its overcurrent and short-circuit protection is bidirectional. Sensata claims the unit protects against a full battery short circuit, with short-circuit protection covering 1.25 kA to 40 kA at 850 V for an inductance range of 0 to 200 µH.
A high-voltage interlock loop (HVIL) is standard. Precharge functionality and an isolation monitor are listed as available options. According to the product page, the unit is suitable for use in ISO 26262 safety-related systems up to an ASIL-B target.
Sensing and Communications
The unit's controller operates on standard 12 V and 24 V low-voltage systems. It senses current across a range of ±1,500 A. Sensata states accuracy is ±10% with the integrated Hall-effect sensor, or ±2% with an optional shunt. Voltage sensing capability reaches 1,200 V.
For vehicle integration, the OmniNode communicates over CAN 2.0B, J1939, and CAN FD protocols. AUTOSAR-compliant software is standard. The company is hosting a webinar titled 'Simplifying Commercial EV Power Distribution with Integrated Off-the-Shelf Solutions' to discuss the challenges in this area.
