Sensata Technologies’ High Voltage Distribution Units Now Powering Megawatt Charging in Production Heavy-Duty Electric Truck
Sensata Technologies (NYSE: ST), a global industrial technology leader in mission-critical sensors and electrical protection, has announced a significant milestone in its electrification strategy. The company’s advanced High Voltage Distribution Units (HVDUs), purpose-built to support megawatt charging for heavy-duty electric trucks, are now integrated into vehicles that have officially entered serial production.
This development marks a major step forward in the electrification of commercial transportation, where scaling electric drivetrains to meet the demanding requirements of long-haul and heavy-duty operations has proven especially challenging. With Sensata’s HVDUs now actively supporting production vehicles, the transition from concept to commercial reality is accelerating.
Enabling Next-Generation Charging Infrastructure
Heavy-duty battery electric trucks, designed to carry substantial loads across long distances, require significantly larger battery packs compared to passenger vehicles. These batteries can reach up to 1 megawatt-hour (MWh) in capacity and must be rapidly recharged to support efficient logistics operations. To address this, truck OEMs are increasingly turning to megawatt charging—capable of delivering charge rates as high as 3 megawatts (MW).
However, this transition places unprecedented technical demands on vehicle power systems. High-voltage components must safely and efficiently manage intense electrical loads, maintain thermal stability, and operate reliably in tough environmental conditions typically encountered in commercial transport.
Sensata’s HVDUs are specifically engineered to meet these requirements. The company’s solutions include Power Distribution Units (PDUs), Charge Units (CUs), and hybrid Charge PDUs (CPDUs), which integrate charging and power distribution capabilities into a single module. These systems are custom-designed to manage electrical power during both battery charging and regular vehicle operation, distributing energy from the battery to various onboard systems.
A Technologically Advanced and Integrated Solution
At the core of Sensata’s electrification portfolio is the ability to deliver technically differentiated products that offer both performance and compact form factor. The company leverages its deep expertise in high-voltage component design to offer complete system solutions that go beyond standard integration.
Each HVDU unit incorporates a suite of in-house developed high-voltage technologies, including:
- Fuses and contactors for safe circuit protection and switching
- Electric Vehicle Charge Controllers (EVCCs) to manage charging communication and control
- Insulation Monitoring Devices (IMDs) for continuous safety monitoring
- Current sensors for real-time power flow measurement
- Control electronics for intelligent system management
- Advanced thermal management, including liquid cooling, to regulate system temperatures
- Sealed IP-rated enclosures for weather resistance and durability
- Optimized busbars and wiring for space- and weight-efficient installations
These integrated systems are engineered to support extremely high power levels and to ensure safe and reliable performance under even the most demanding operating conditions. They are also designed with modularity and customization in mind, making them adaptable to different OEM platforms and vehicle architectures.
Supporting the Shift to Low-Carbon Transportation
With governments and regulatory agencies around the world tightening emissions standards for commercial fleets, the pressure on manufacturers to deliver zero-emission vehicle options has never been greater. This is especially true for freight and logistics operators, who are looking to decarbonize operations without sacrificing reliability or uptime.
Sensata’s HVDU technology plays a critical enabling role in this transition. By supporting megawatt-level charging, the company is helping OEMs address a key bottleneck in electric truck adoption: charging speed. Faster charging translates to reduced downtime and improved vehicle utilization—two factors that are essential for fleet operators to justify the transition to electric.
In addition to performance, Sensata places a strong emphasis on safety, an essential consideration when working with high-voltage systems. Its HVDUs feature enhanced electrical and thermal protections, ensuring system integrity even in fault conditions.
Executive Commentary
Mark McBrine, Product Line Owner – Electrification at Sensata, emphasized the significance of the company’s role in this space.
“Our high voltage distribution units will play a crucial role in advancing the electrification of heavy vehicles, and we are proud to contribute to a more sustainable future on leading manufacturer’s next-generation trucks,” said McBrine. “We’ve engineered these systems to meet the industry’s toughest standards, and we’re excited to see them now operating in real-world applications.”
Brian Wilkie, Executive Vice President of Performance Sensing, Vehicle Business at Sensata Technologies, added:
“The use of our megawatt charging solutions on electric trucks in production represents a significant milestone for Sensata’s electrification portfolio and highlights our commitment to innovation and to solving our customers’ toughest challenges. We’re not just supporting the industry’s transition—we’re actively accelerating it.”
Looking Ahead: Industry Engagement at ACT Expo
Sensata Technologies will be showcasing its high-voltage electrification solutions, including its HVDUs, at the upcoming Advanced Clean Transportation (ACT) Expo, taking place April 28–30 in Anaheim, California. The company invites industry stakeholders, OEM partners, and fleet operators to visit booth 6811 to learn more about its products and discuss opportunities for collaboration.
The ACT Expo is one of North America’s premier events focused on clean transportation technology, and Sensata’s presence underscores its commitment to staying at the forefront of electrification innovation.
A Vision for the Future of Commercial EVs
As heavy-duty electric trucks begin to scale, solutions like Sensata’s HVDUs will be vital to enabling this shift. The successful deployment of these systems in production vehicles is not just a technological achievement—it’s a clear indicator of market readiness and demand.
With a growing product portfolio, a focus on solving real-world customer challenges, and a strategic vision aligned with sustainability goals, Sensata Technologies is well-positioned to be a leading enabler of the commercial vehicle sector’s electric future.
About Sensata Technologies
Sensata Technologies is a global industrial technology company striving to create a safer, cleaner, more efficient and electrified world. Through its broad portfolio of mission-critical sensors, electrical protection components and sensor-rich solutions, Sensata helps its customers address increasingly complex engineering and operating performance requirements. With more than 18,000 employees and global operations in 14 countries, Sensata serves customers in the automotive, heavy vehicle & off-road, industrial, and aerospace markets.