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When it comes to electric vehicles, two concerns dominate the minds of drivers: range and safety. Both are directly tied to one critical factor — the temperature of the battery pack. Too cold, and range drops sharply. Too hot, and safety risks emerge. Inside this “energy core,” reliable NTC temperature sensors play a decisive role in ensuring performance and protection.

The Thermal Challenge in EV Batteries

Unlike combustion engines, which tolerate a wider temperature swing, lithium-ion battery packs operate within very strict limits.

• Cold weather issue: In sub-zero climates, range can shrink by 30–40%. For example, a 300-mile rated EV may only deliver 180 miles when parked outside overnight in freezing conditions.
• Heat during fast charging: When pack temperatures exceed 45°C, cell degradation accelerates, raising the risk of reduced lifespan or even thermal runaway.
• Imbalance risk: Even a 5°C difference between cells can cause uneven charging, reducing overall battery life.

To counter these problems, modern EVs use intelligent thermal management systems that heat in the winter and cool during fast charging in the summer.

NTC Sensors: Building a Multi-Layer Monitoring Network

In today’s EV battery packs, NTC temperature sensors are distributed at multiple points to provide real-time, accurate feedback:

• On individual cells: Sensors track each cell’s temperature, signaling the Battery Management System (BMS) when a hotspot approaches 48°C. This allows targeted cooling before risks escalate.
• On coolant channels: Sensors at inlet/outlet points ensure efficient heating or cooling cycles. For instance, once coolant reaches 25°C in winter, the system can stop heating to save energy.
• On the pack casing: External sensors measure ambient impact, such as cold starts at –10°C, enabling pre-heating to keep cells above 15°C for optimal activation.

This cell–coolant–casing tri-layer approach gives engineers precise control over pack behavior.

Balancing Range and Safety

The real value of NTC sensors lies in enabling dynamic adjustment between performance and protection.

• At 40°C, the BMS reduces charging power (e.g., from 120kW to 80kW) to prevent overheating.
• At 10°C in winter, the system allows higher charging current, reducing waiting time without sacrificing battery life.

The result?  EVs can fast-charge to 80% in 30 minutes while extending pack life cycles to over 1,200 — compared to an industry average of 800.

According to IEA and EVTank, global EV sales exceeded 17 million in 2024, with a 26% CAGR over the past three years. By 2025, sales are projected to surpass 22 million, and by 2030, penetration could exceed 40%. With this rapid adoption, battery thermal safety is under global scrutiny — making high-reliability sensors not optional, but essential.

Why Shiheng Electronics?

At Shiheng Electronics, we provide precision-engineered NTC sensors tailored for EV battery systems:

• Proven accuracy and fast response in dynamic charging environments.
• Durable construction for harsh vibration, humidity, and long-term stability.
• Customizable probe and harness designs for direct pack integration.
• Trusted supplier with 20+ years of experience in thermal sensing.

With every data point, our sensors help OEMs deliver both longer range and greater safety — ensuring EV drivers have confidence on the road, in every season.