Current Sensing Modules
Smart Battery Clamp
Smart, Customizable Monitoring for Next-Generation Battery Systems
Designed for Intelligent Energy Management
A design study that integrates precise current sensing and battery connectivity into a compact, high-performance package.
Smart Battery Monitoring Clamp Assembly
The Smart Battery Clamp is a customer-specific electronic monitoring module designed for automotive, e-mobility, and renewable energy systems.
Engineered to Your Specifications
Key Elements of the Smart Battery Clamp Design
1
Shunt Resistor Integration
Built-in for precise current measurement; compatible with ±5A to ±500A input ranges.
2
Busbar Design
Custom copper or alloy busbars tailored for high-current applications.
3
Hall Effect Sensor
Features the Melexis 91208 for contactless, reliable current sensing.
4
Custom Terminal Layouts
Assembly-friendly designs using press-fit or rivet connections.
5
Injection-Molded Housing
Provides electrical insulation and environmental protection.
6
Scalable Manufacturing
In-house production for shunt and busbar assemblies ensures high quality and cost efficiency.
Shunt Performance Characteristics
1
Energy Battery Monitoring Units (BMU)monitoring
Accurate current and voltage monitoring for high-performance batteries.
2
Overcurrent protection Intelligent Battery Sensors
Used in automotive and electric vehicle power management systems.
3
E-Mobility & High-Voltage Systems
Designed for hybrid and electric drivetrains.
4
State-of-Charge & State-of-Health Monitoring
Real-time battery health diagnostics.
5
Solar & Renewable Energy Systems
Optimized for energy storage and load balancing.
6
Functionally Safe Designs
Dual-sensing (shunt + Hall) enables redundancy and fail-safe operation.
7
Automotive-grade design
Support throughout the partnership
Why Choose Smart Battery Clamps?
1
Customer-Specific Design
Tailored to your application, from terminals to sensing method
2
Flexible Sensing Technology
Choose from shunt, Hall effect, or hybrid combinations
3
Compact Assembly
Integrates multiple components into one space-saving unit
4
Robust Packaging
Molded housing protects electronics in harsh environments
5
Functional Safety Options
Dual-sensing technology supports ISO 26262-compliant systems
Shunt Performance Characteristics
| Parameter | Typical Value | Unit |
|---|---|---|
| Primary input current range | ±5 - ±500 | A |
| Voltage measurement range | ±5 - ±800 | V |
| Maximum power | 60 | W |
| Operation temperature range | –50 - 150 | °C |
Frequently Asked Questions
Its integration of current sensors (shunt or Hall) with robust packaging and customizable connections enables real-time battery diagnostics in a compact module.
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