Sensata Technologies Introduces Next-Generation SIM200 Insulation Monitoring Device for Enhanced Safety in High-Voltage Systems
Sensata Technologies has officially unveiled its latest innovation, the SIM200 Insulation Monitoring Device (IMD), a next-generation solution aimed at advancing safety in the rapidly evolving electric vehicle (EV) ecosystem. Designed to provide continuous active monitoring of unearthed (Isolated Terra) DC systems, the SIM200 is engineered for use in a variety of high-voltage applications, including EV charging stations, electric vehicles, and other critical systems operating above 60 VDC.
The Importance of Insulation Monitoring in High-Voltage Systems
In high-voltage electrical systems, insulation is crucial to ensuring safe operation. Electrical isolation is achieved through various non-conductive barriers, such as insulation coatings on cables, plastic housings for components, and maintaining adequate physical distances between high-voltage elements. However, insulation breakdown or failures can lead to unintended current flow, which increases the risk of electrocution, equipment damage, or even catastrophic system failures.
Insulation Monitoring Devices (IMDs) play a vital role in continuously assessing the integrity of insulation in high-voltage systems. These devices detect insulation failures and prevent hazardous conditions by identifying leakage currents before they become critical threats. As the electrification of transportation and industrial applications continues to expand, the need for reliable IMDs has never been greater.
SIM200: Advanced Technology for Continuous Monitoring
The SIM200 IMD sets itself apart through its advanced signal injection algorithm and sophisticated processing capabilities. Unlike conventional IMDs that may only operate under specific conditions, Sensata’s innovative technology enables the SIM200 to provide “always-on” monitoring—even when the system is turned off or undergoing significant voltage fluctuations. This feature ensures that potential faults are detected in real-time, allowing for immediate corrective actions.
A distinguishing feature of the SIM200 is its ability to measure total stored capacitance in the system. This capability is particularly critical in next-generation megawatt charging applications, where high levels of stored electrical energy pose unique safety challenges. By monitoring total capacitance, the SIM200 ensures compliance with future insulation monitoring specifications and enhances the overall safety of high-powered charging infrastructure.
How the SIM200 Works: A Closer Look at Its Functionality
The SIM200 leverages technology developed from Sensata’s acquisition of Sendyne Corp in 2021. It operates by injecting a small voltage signal through isolation resistors onto both the positive and negative high-voltage rails of an Isolated Terra system. These voltage pulses alternate between the positive and negative rails at predefined intervals, and the system continuously monitors the responses to detect any abnormalities. If an issue is identified, the IMD can trigger safety protocols, including system shutdown, to prevent potential hazards.
This advanced methodology enables the SIM200 to detect even subtle insulation failures before they escalate into significant risks. Its real-time monitoring capabilities make it an essential safety component for a wide range of applications, including:
- Electric Vehicles (EVs): Ensuring insulation integrity in battery systems and powertrains.
- Charging Infrastructure: Providing safety monitoring in DC fast chargers and megawatt-scale charging stations.
- Industrial High-Voltage Systems: Enhancing reliability in high-power DC applications such as renewable energy storage and power distribution.
Versatile and Industry-Compliant Design
The SIM200 is designed to integrate seamlessly into a variety of high-voltage platforms. Available in multiple configurations to accommodate systems ranging from 60V to 1500V, the device is adaptable to diverse application requirements. It is UL 2231-2 recognized and has been tested in accordance with IEC 61557-8 standards, ensuring compliance with global safety and performance regulations.
To enhance interoperability, Sensata has developed the SIM200’s communication framework in collaboration with leading Original Equipment Manufacturers (OEMs). The device features dual dedicated fault state outputs and robust self-diagnosis functionality, allowing for seamless integration into existing safety systems. Additionally, the modular CAN 2.0B interface provides detailed system information, facilitating real-time diagnostics and preventive maintenance.
Driving the Future of High-Voltage Safety
Alice Martins, Vice President and General Manager of Sensata’s Industrial Solutions Business, emphasized the company’s commitment to advancing high-voltage safety technology:
“Sensata’s SIM200 delivers a robust insulation monitoring device with total capacitance measurement and continuous monitoring capabilities to enable the next generation of high-voltage systems. It is another product that drives our mission of supporting OEMs around the world as they look to create a cleaner and more electrified world.”
The launch of the SIM200 underscores Sensata’s broader efforts to develop innovative solutions that enhance safety, efficiency, and sustainability in the electrification movement. As high-voltage systems become increasingly complex, the need for reliable insulation monitoring solutions will continue to grow. By providing an advanced and versatile IMD, Sensata is helping OEMs and system integrators address these evolving challenges.
Experience the SIM200 at ACT Expo 2025
Sensata Technologies will showcase the SIM200 Insulation Monitoring Device at the upcoming Advanced Clean Transportation (ACT) Expo, taking place from April 28 to 30. Attendees are invited to visit Sensata’s booth (#6811) to learn more about the SIM200 and other cutting-edge insulation monitoring solutions.
Sensata Technologies
Sensata Technologies is a global industrial technology company dedicated to creating a safer, cleaner, and more efficient electrified world. With a broad portfolio of mission-critical sensors, electrical protection components, and sensor-rich solutions, Sensata supports customers across multiple industries, including automotive, heavy vehicle & off-road, industrial, and aerospace. The company’s commitment to innovation and engineering excellence enables its partners to navigate the challenges of modern electrification with confidence.
With over 18,000 employees operating across 14 countries, Sensata Technologies continues to drive the development of next-generation safety and performance solutions for an increasingly electrified world.
