New Strategies For High Voltage Fault Management In Next-Gen EVs

Presented by:

Mark McBrine, Electrification Product Line Owner, Sensata Technologies
Keith Washburn, Senior Mechanical Engineer, Electrification, Sensata Technologies

Mar 11, 2026, 10:30 am EDT

As electric vehicles push toward more efficient and higher voltage architectures, the limitations of traditional fuse and contactor protection are becoming harder to ignore. False triggering, single‑use hardware, and complex redundancy add cost, weight, and downtime. This webinar addresses these challenges head‑on and introduces an innovative approach for high voltage fault management.

Join the session where we will walk through the engineering principles behind passive and active fault clearing and show how resettable protection can minimize nuisance trips, improve serviceability, and simplify system integration. Drawing on validation data up to 16 kA at 1 kV, we will compare conventional contactor plus fuse and pyrofuse designs to a new approach that combines these functions into a single package, evaluating each for safety, thermal performance, cost, and complexity. Attendees will leave with a practical framework for specifying robust, adaptable electrical protection that reduces component count, lowers thermal losses, and supports next‑generation EV architectures.

Key takeaways:

- Discover how innovative, resettable protection strategies can reduce system cost, weight, and complexity while enhancing safety.

- Gain data-driven perspectives on managing high magnitude fault currents and minimizing downtime in next-generation EV architectures.

- Learn how collaborative approaches and system-level thinking are driving the industry toward more robust and adaptable electrical protection solutions.

All Sessions: March 2026 Conference

A Virtual Conference on EV Engineering: March 9-12, 2026.
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