What if batteries could warn before failure? New sensors detect hydrogen during early stages, enabling faster response and improved safety in EV systems.
Posifa Technologies has introduced the PGS5100 series hydrogen sensors designed to enable early detection of gas buildup in EV battery systems and other safety critical environments.
The MEMS based thermal conductivity sensors are engineered to identify hydrogen during the initial off gas phase inside battery packs, a stage that can occur minutes before heat escalation or ignition. By detecting this early signal, the system allows timely mitigation actions, improving overall safety in electric vehicles and industrial applications.
Built on the company’s earlier PGS4100 platform, the new series delivers a ten times faster response while measuring hydrogen concentrations across a 0 percent to 25 percent range. The sensors operate by analysing changes in thermal conductivity within gas mixtures, enabling precise detection without relying on reactive sensing elements. Integrated humidity and barometric pressure sensors further enhance accuracy by compensating for environmental variations such as temperature, altitude, and moisture levels.
A key advantage of the PGS5100 lies in its durability and stability in harsh conditions. The sensors are resistant to condensation and non reactive to contaminants, supporting long term operation in enclosed battery systems, fuel cells, and industrial environments. With a service life exceeding 15 years, the design also addresses reliability challenges associated with conventional catalytic sensors.
From an integration perspective, the sensors support MODBUS RTU over RS 485 communication, with CAN compatibility planned. They feature a 100 millisecond response time, 200 millisecond warm up time, and operate on a 5 volt supply with low power consumption. The compact IP6K9 rated enclosure and automotive grade connector enable deployment in embedded safety systems requiring continuous, real time monitoring.
“Thermal runaway is not always instantaneous, and hydrogen can appear minutes before ignition,” said Peng Tu, President and CEO of Posifa Technologies. “The PGS5100 is designed to detect that signal reliably inside the battery pack, helping OEMs trigger mitigation and improve response time.”
