Sensata’s off-the-shelf OmniNode consolidates high-voltage distribution for commercial EVs

EV Engineering News

Posted September 11, 2026 by Chris Ruoff & filed under Newswire, The Tech.

Sensata Technologies has introduced the OmniNode, a patent-pending, off-the-shelf high-voltage power distribution unit for battery-electric commercial vehicles. It combines DC charging, switching, circuit protection, sensing, diagnostics and communications in a single system, built from Sensata components including contactors, fuses and current sensors.

The OmniNode is designed for on- and off-road commercial vehicles, including Class 5 and above trucks and buses. Sensata says the standardized unit reduces reliance on custom-engineered solutions, cutting integration and validation work and simplifying sourcing for OEMs. One design can also be reused across vehicle programs with different applications and configurations, according to the company.

The product page lists an operating voltage of up to 1,000 V DC and a continuous current rating of 500 A. A boost rating allows 700 A for 15 minutes at 60° C, and current derates above 60° C ambient. The unit operates at ambient temperatures from −40° C to 85° C, and is rated for altitudes up to 4,000 m. It needs no active cooling, the company says, even in low airflow.

Overcurrent protection covers up to 1,250 A at 850 V. Short-circuit protection spans 1.25 kA to 40 kA at 850 V for inductance of 0 to 200 µH, and Sensata says the unit protects against a full battery short circuit. Protection is bidirectional.

The unit includes a high-voltage interlock loop (HVIL), and dielectric withstand is rated at 2.7 kV between high-voltage circuits and 4.3 kV between the high- and low-voltage sides. Precharge and an isolation monitor are available as options.

The controller runs on 12 V and 24 V nominal low-voltage systems and senses current across ±1,500 A, to ±10% accuracy with its Hall-effect sensor or ±2% with an optional shunt. Voltage sensing reaches 1,200 V. It communicates over CAN 2.0B, J1939 and CAN FD, and AUTOSAR software is standard. According to the product page, it is suitable for use in ISO 26262 safety-related systems up to an ASIL-B target.

Don’t miss Sensata’s webinar next week: Simplifying Commercial EV Power Distribution with Integrated Off-the-Shelf Solutions, which covers the challenges of commercial EV power distribution.

“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,” said Brian Wilkie, Sensata’s Executive Vice President and President of Aerospace, Defense and Commercial Equipment.

Source: Sensata Technologies

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