Electric vehicle (EV) sensors are devices that are designed to detect, control, and monitor different aspects of electric vehicles and their surroundings such as performance, safety, malfunctions, and system failures. In addition, these sensors play a crucial role in measuring the service life of batteries, determining EV-related issues, assisting in real-time data collection, and regulating motor torque. Current, position, temperature, and voltage are the key parameters that are evaluated for the optimum performance of EVs.
Evaluating the Key Driving Forces of EV Sensor Industry
According to Allied Market Research, the electric vehicle sensor market is expected to generate a revenue of $37.4 billion by 2031 from $9.6 billion in 2021, registering a CAGR of 15.1% from 2022 to 2031. This increase in revenue is majorly due to expansion of EV charging infrastructure and surge in adoption of EVs. The International Energy Agency, an autonomous intergovernmental organization based in Paris, revealed that the sale of EVs reached approximately 3 million in the first quarter of 2024, which was around 25% higher as compared to 2023. Furthermore, according to industry experts, among all the passenger cars sold in the U.S., EVs are projected to account for 25-30% of these by the end of 2030.
Assessing the Major Functions of EV Sensors
The most important functions of EV sensors include enhancing personalized in-cabin experiences, supporting advanced driver-assistance systems (ADAS), and controlling battery and thermal management. Multiple sensors are deployed in EVs to enhance personalized in-cabin experiences. For instance, to enable touchless interaction with infotainment systems, gesture recognition sensors are equipped in EVs, thus offering seamless experiences to drivers and passengers. Moreover, a few EV in-cabin systems make use of sensors that make a significant contribution in adjusting temperature, changing seat settings, modifying interior lightings, and opting for suitable audio. EV sensors further serve as an essential part of in-cabin safety. For example, infrared and camera sensors integrated in the driver monitoring systems help in inspecting and tracking pedal pressure, driver alertness, and steering control. These features are imperative as they activate alerts and the sensors take control if the driver becomes drowsy or if dangerous road conditions are detected.
EVs also comprise heads-up displays that demonstrate crucial information, including navigation, speed, and warnings directly into the driver’s line of sight. The heads-up displays receive real-time data from sensors and fusion algorithms from GPS, speedometer, and ADAS. Furthermore, EVs are incorporated with interior sensors that send “child left behind” alerts to drivers reminding them to check rear seats before exiting the vehicle, thereby preventing accidents with unattended children or pets. These sensors also play an essential role in averting heat strokes and other temperature-related risks among unsupervised kids. Moreover, blind spot detection is enabled by ultrasonic sensors that alerts drivers about the side-approaching vehicles or lane changing of vehicles. In addition, pressure monitoring systems are fitted with sensors to assure pressure in the tires meets the standard requirements and is at safe levels.
On the other hand, diverse automated functions like emergency braking, route planning, complete self-driving, collision avoidance, adaptive cruise control, and lane keeping assistance are facilitated with the help of sensors equipped in EV ADAS. For instance, safety systems and autonomous navigation are embedded with LiDAR sensors that exhibit capabilities such as object detection and 3D mapping, thus enhancing the overall safety during driving. Additionally, to ensure optimum and reliable EV performance in extreme weather conditions, including rainfall, snowfall, and heavy fog, millimeter-wave radar sensors are instrumental. Moreover, EV manufacturers have focused on developing advanced sensor technologies with improved signal processors and more directive antennas, which help minimize the risk of moisture buildup and impact of radar’s narrower field of view. These advancements enable EV ADAS to operate reliably, even when the line of sight is obstructed.
ADAS are in-built with advanced sensor systems, which considerably enhance the capabilities by offering a detailed understanding of the driving environment. LiDAR enables high-definition 3D mapping, whereas radar delivers reliable performance in all weather conditions. These technologies are supported by night vision sensors and conventional cameras that collect essential visual information to ensure that the vehicle moves safely and efficiently.
These sensors help the vehicle identify road signals such as road signs, cones, and traffic lights, enabling compliance with traffic regulations and adapting to road scenarios. They also detect lane markings to keep the EV correctly positioned within its lane. In addition, the presence of surrounding vehicles, including trucks, cars, motorcycles, and bicycles as well as pedestrians is detected with the help of these sensors, thereby preventing collisions. To enable effortless parking, cameras and ultrasonic (sonar) sensors operate collectively and provide accurate input for both manual and automated parking systems, as well as for low-speed maneuvers in congested spaces.
Inertial measurement units and GPS sensors collect data on location and motion to further improve vehicle awareness, thereby allowing the ADAS to facilitate automated lane changes, real-time route planning, and emergency braking. Inertial measurement units, which include accelerometers and gyroscopes, detect acceleration and rotation, which help to predict vehicle behavior and support accurate control system responses.
Sensor technology also plays a vital role in EV battery management. The battery’s state of charge and state of health is monitored continuously with the help of advanced sensors, thus ensuring balanced electrical loads between individual cells. To prevent overheating, these sensors are essential, as they regulate voltage and temperature, thus reducing the risk of thermal runaway and extending battery life.
Humidity sensors embedded in the battery pack measure moisture levels to protect against condensation. This is attributed to the fact that moisture buildup can hamper the functioning of internal components. These sensors are fundamental in heat reduction during rapid charging or discharging cycles, lowering the stress on battery cells and helping to limit long-term degradation. In some EV models, fiber Bragg grating sensors are integrated into the battery assembly. These sensors monitor resistance changes that could indicate potential mechanical strain or structural damage, allowing timely maintenance.
To prevent issues such as demagnetization or thermal damage, motor inverter temperatures are constantly monitored by sensors. Using advanced thermocouples or infrared sensors, the system measures temperature gradients across the inverter’s power electronics. This helps maintain a stable thermal environment, improving motor efficiency and extending component lifespan.
In addition, sensors manage temperature regulation in the vehicle’s HVAC systems. These systems control thermal conditions in cabin, battery units, power electronics, motor assemblies, onboard chargers, and external heat exchangers. As a result, all these diverse sensors collectively contribute to optimum vehicle performance and improved safety, thereby enhancing overall driver and passenger experience.
Final Word
EV sensors have gained high traction due to their capabilities of controlling, detecting, and monitoring various aspects of EV and their surroundings. Enhancing personalized in-cabin experiences, ensuring optimum performance of ADAS, and supporting battery and thermal management are the key features of EVs, which require a wide range of sensors. With rise in penetration of EVs, the integration and advancement of EV sensors are expected to intensify in the coming future.
