Applications of First Sensor Temperature Sensors in the Automotive Industry

Temperature is one of the most sensitive parameters in automotive power systems and safe operation. Whether it is engine overheating in traditional vehicles or thermal runaway in new energy vehicle batteries, abnormal temperatures can lead to serious safety incidents or performance degradation. As the automotive industry accelerates towards intelligent and electric vehicles, the requirements for temperature sensors have evolved from simple measurement to comprehensive guarantees of high reliability, fast response, anti-interference, and long lifespan. Nexisense focuses on automotive-grade temperature sensors, using precision 316L stainless steel structures, laser welding technology, and high-performance digital circuit design to provide stable and reliable temperature monitoring solutions for key scenarios such as bus fire prevention, new energy thermal management, and motor protection. This article explores typical applications, technical characteristics, and future trends of temperature sensors in the automotive industry.

Traditional Vehicles: Bus Fire Prevention and Engine Protection

During hot summer conditions, bus fire incidents have become a public concern. Causes often relate to vehicle aging, insulation deterioration, and poor cooling in rear-engine compartments. Drivers cannot easily detect abnormal temperatures inside the engine compartment, and once a critical point is reached, fires may easily occur.

To address this, some urban bus companies began equipping rear-engine buses with temperature sensors years ago to monitor engine compartment temperature in real time and trigger automatic alarms. When the temperature exceeds a preset threshold (e.g., 120°C or higher inside the engine compartment), the system immediately triggers audible and visual alarms, and may even cut power or reduce output, greatly reducing the risk of fire.

Nexisense temperature sensors perform excellently in this scenario: the probe is made of 316L stainless steel, corrosion-resistant and vibration-resistant, with an overall protection rating of IP65 (optional IP68). The response time is as fast as a few seconds, with long-term stability. Built-in high-performance digital circuits, with strict EMC design, provide excellent RF interference, surge voltage, and polarity protection, meeting IEC and CE (EMC) standards and ensuring stable and reliable signals in complex electromagnetic environments.

New Energy Vehicles: Battery Thermal Management and Safety Core

In hybrid and pure electric vehicles, battery temperature directly determines energy output efficiency, lifespan, and safety. The optimal operating temperature for lithium-ion batteries is usually 15°C–45°C; temperatures that are too high can cause thermal runaway, while too low temperatures significantly reduce discharge capacity and charging efficiency. Therefore, battery management systems (BMS) must be equipped with high-precision, fast-response temperature sensors to monitor each module or even individual cells in real time.

Currently, NTC thermistor temperature sensors are the mainstream choice for battery temperature monitoring due to their high sensitivity and cost advantages. Nexisense offers multiple NTC packaging options; the probes are compact and flexible for installation, directly embedded in battery modules or attached to tabs or casing surfaces. Sensor accuracy reaches ±0.5°C, combined with digital compensation algorithms to ensure consistent measurements across the full temperature range.

Battery cooling systems (liquid or air cooling) also rely on temperature sensor feedback for active thermal management. When the temperature approaches the upper limit, the system automatically activates cooling pumps or fans to keep the battery within the optimal range, extending lifespan, improving fast-charging capability, and enhancing safety.

Motor Temperature Monitoring: Key to Stator Winding Protection

The motor is the core power component in new energy vehicles, and the stator winding temperature determines motor lifespan and performance. When winding temperature exceeds 140°C–150°C, insulation aging accelerates, and prolonged overheating can cause short circuits or motor burnout.

To ensure safe and efficient motor operation, temperature sensors must be installed inside or near the stator windings. Sensor placement requires a compact design, high voltage and temperature resistance, mechanical stress tolerance, and high dielectric strength to prevent arc-over or interference from high-voltage windings.

Nexisense automotive-grade temperature sensors feature compact designs and high-strength laser welding, with dielectric strength up to several kilovolts. They support PT100, PT1000, NTC, and other temperature sensing elements, meeting various motor manufacturers’ integration requirements. The sensors have high vibration resistance, suitable for the intense vibrations generated by high-speed motor rotation, and have been widely deployed in multiple new energy vehicle motor systems.

Technical Features: High Reliability and Strong Anti-Interference

• Structural Reliability: 316L stainless steel probe and connector, laser-welded seal, IP65–IP68 protection, oil, water, and corrosion resistance, suitable for engine compartments and battery packs.

• Fast Response: Short thermal response time (typically <5s), suitable for dynamic temperature monitoring.

• High Accuracy and Stability: Full-range temperature compensation, accuracy ±0.5°C–±1°C, minimal long-term drift.

• Strong Anti-Interference: Built-in precision digital conversion circuits, tested against RF, surge, ESD, and meeting automotive EMC requirements.

• Wide Supply and Protection: Wide supply range (typically 9–36VDC), with reverse polarity and short-circuit protection.

These features allow the products to meet traditional automotive needs and handle challenges of high voltage, high current, and strong electromagnetic environments in new energy vehicles.

Development Trends: Intelligence and Multi-Parameter Integration

• Deep integration with BMS and VCU, supporting CAN, LIN, and other in-vehicle communication protocols for real-time temperature data sharing.

• Multi-point array layout for grid monitoring of battery packs, enhancing early warning capabilities for thermal runaway.

• Integration with pressure, humidity, and gas sensors to form multi-parameter thermal management modules.

• Wireless and low-power designs, suitable for wireless BMS and solid-state battery architectures.

Nexisense continues to invest in R&D, launching next-generation products with digital interfaces and edge computing support, providing the sensing foundation for intelligent connected vehicles and the solid-state battery era.

FAQ: Common Questions about Temperature Sensors in the Automotive Industry

Why are high requirements placed on battery temperature sensors in new energy vehicles?
Battery temperature directly affects safety, lifespan, and performance; overheating can trigger thermal runaway, and overcooling reduces energy output, requiring high-precision, fast-response, and reliable monitoring.

What are the differences in applicability between NTC and PT100/PT1000 in vehicles?
NTC has high sensitivity and low cost, suitable for individual cells and battery modules; PT series have good linearity and high precision, commonly used for motor windings and high-temperature monitoring of critical components.

How to prevent temperature sensor failure in engine compartments or motors?
Use IP67/IP68 protected, stainless steel encapsulated, vibration- and EMI-resistant products, and ensure installation avoids extreme heat sources and mechanical impacts.

How does sensor accuracy affect vehicle performance?
High accuracy enables precise thermal management, extending battery and motor lifespan and improving energy efficiency and fast-charging capability; low accuracy may cause protection strategy misjudgments.

Conclusion

From bus engine compartment fire prevention to new energy vehicle battery thermal management and motor winding protection, temperature sensors have become the cornerstone of automotive safety, efficiency, and reliability. Nexisense high-reliability temperature sensors, with compact structure, fast response, strong anti-interference, and automotive-grade design, provide stable and reliable temperature monitoring solutions for both traditional and new energy applications. As electrification and intelligent vehicle trends advance, temperature sensing requirements will only increase. Choosing a supplier with strong technical accumulation and engineering experience ensures vehicle safety, enhances user experience, and supports the automotive industry's transition to greener and smarter development. In the future, temperature will no longer be an invisible threat, but a controllable core variable.