The future of energy storage depends on smarter systems, not simply on building bigger batteries.
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As renewable energy expands, storage systems must be designed for greater reliability, efficiency, and safety. Modern energy storage systems do more than just store power. They monitor, adapt, and protect themselves in real time.
Advanced sensors are often considered the nervous system of modern battery energy storage systems (BESS). These powerful sensors detect shifts in temperature, pressure, and humidity before they escalate into failure.
The right sensors are vital to ensure smooth, durable storage, maximize performance, and prevent overheating. This article looks at a range of essential sensors able to futureproof a battery energy storage system design.
Why Sensors are Important in Battery Energy Storage System Design
Battery storage performance relies on maintaining precise operating conditions. Sensors contribute to a well-designed BESS in a number of different ways:
- Enhancing safety by detecting temperature, humidity, or pressure anomalies to prevent fires or explosions
- Optimizing performance and monitoring cell temperature and voltage in order to maximize power output and efficiency
- Enabling predictive maintenance by identifying potential failures early, reducing maintenance costs, and downtime
- Extending battery lifespan by maintaining ideal conditions to maximize longevity
Essential Sensors for a Battery Energy Storage System
A broader network of sensors is required to ensure peak performance, safety, and longevity as part of a truly optimized battery energy storage system.
Advanced sensors guard against hazards and inefficiencies, monitoring everything from temperature to coolant leaks. Instead of reacting to faults, these sensors deliver real-time insights that enable predictive maintenance and cut downtime.
A range of critical sensors is required to elevate BESS performance and strengthen energy storage systems against potential risks.
Thermometrics Coolant Temperature Sensor
The Thermometrics Coolant Temperature Sensor tracks liquid coolant temperatures to improve efficiency and prevent overheating.
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Key features of this sensor include:
- High accuracy, with the ability to provide precise temperature readings for performance and safety.
- Durable design able to function under extreme conditions and vibrations.
- A compact and versatile design, able to integrate into various systems with ease.
- Made from durable materials, ensuring long-term reliability in industrial settings.
- Thermal optimization, designed to improve battery performance and longevity.
Thermometrics JS8845 Pipe Clip Surface Temperature Sensor
The Thermometrics JS8845 is a surface-mounted sensor designed to enable efficient system temperature regulation via the precise temperature monitoring of gases or fluids in pipes.
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Key features of this sensor include:
- Easy installation, with a spring-loaded clip allowing rapid attachment to 15–18 mm pipes.
- High sensitivity, ensuring accurate temperature readings for consistently reliable data.
- A robust IP57-rated design offering dust and water resistance.
- A wide operating temperature range from -40 °C to +125 °C.
- A compact, versatile sensor able to connect to various systems via integrated secure connectors.
NovaSensor NPI-19 I2C Pressure Sensor
The high-accuracy NovaSensor NPI-19 I2C Pressure Sensor is a digital sensor ideally suited to monitoring liquid or gas pressure in industrial applications and battery energy storage systems.
This sensor’s I2C interface allows for seamless integration into automation systems, ensuring system efficiency and safety.
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Key features of this sensor include:
- High precision, with a linearity of ±0.25 % full-scale output (FSO) and a total error band of ±1 % FSO.
- A wide pressure range, from 2.5 psi (17 kPa) to 300 psi (2068 kPa).
- Digital output, with precise data transmission via 14-bit I2C output.
- Robust construction, with stainless steel body and diaphragm ensuring durability and media isolation.
- Suitability for a range of applications, including hydraulic systems, industrial process control, corrosive fluid and gas measurement, and more.
NovaSensor NPI-19 Series Medium Pressure Sensors
The high-sensitivity NovaSensor NPI-19 Medium Pressure Sensor enables medium-pressure monitoring in battery energy storage systems. Its compatibility with various pressure ranges and compact design make it ideally suited to use in complex monitoring systems.
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Key features of this sensor include:
- High reliability, with a solid-state design ensuring consistent durability.
- A 316L stainless steel with ISO-certified sensor design that is built to last.
- High precision, with 0.1 % typical linearity and ±0.5 % static accuracy.
- Advanced temperature compensation calibrated from 0 °C to 70 °C.
- High sensitivity, with 100 mV full-scale output with 1.0 mA excitation.
- Versatile pressure ranges, from 0 to 15 psig (0 to 1 bar) up to 0 to 250 psig (0 to 17 bar), in either absolute or gauge configurations.
- Customizable configurations, with multiple standard and custom pressure port options available.
Telaire T9602 IP67 Harsh Environment Humidity and Temperature Sensor
The Telaire T9602 is a fully calibrated temperature-compensated sensor designed to measure temperature and humidity. This sensor is built for reliable performance in harsh environmental conditions, and is encased in a water-resistant, IP67-rated package.
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Key features of this sensor include:
- High accuracy, with the ability to measure to ±2 % RH and ±0.5 °C accuracy.
- Digital output, offering either I2C interface or Pulse Density Modulated (PDM) output, convertible to an analog signal where required.
- Low power consumption, with an energy-efficient design making it ideal for battery-powered applications.
- Flexible installation, with various cable lengths available and flexible mounting options.
- Durable construction designed to protect sensitive parts, ensuring long-lasting performance in harsh environments.
- Simple integration, with a compact size allowing easy installation within a range of systems.
Telaire EHRH Humidity Transmitter
The high-performance Telaire EHRH Humidity Transmitter enables reliable and accurate humidity monitoring in battery energy storage systems. This sensor is able to provide stable long-term measurements, ensuring optimal operating conditions and helping to prevent moisture-related damage.
Its analog and digital output options allow the Telaire EHRH Humidity Transmitter to be easily integrated into automation and HVAC systems, enabling efficient climate control.
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Key features of this sensor include:
- High accuracy, offering ±2 % RH within a 30-95 % RH range.
- Analog output options, including support for 0-5 v, 0-10 v, and 4-20 mA outputs.
- Selectable outputs, including active and passive temperature output options.
- Rugged design, including a waterproof housing that is ideally suited for use in challenging environments.
- Optional temperature output.
Telaire T9501 Humidity & Temperature Transmitter
The cost-effective Telaire T9501 offers accurate humidity and temperature measurements across a wide range of applications. Its water-resistant IP67-rated, design ensures reliable performance, even in the most challenging environments.
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Key features of this sensor include:
- Supplied pre-calibrated and temperature-compensated to enable immediate integration.
- Digital communication via RS485 MODBUS protocol ensures efficient data transmission.
- High precision, with ±0.5 °C temperature accuracy and ±2 % RH accuracy (20-80 % RH) with 14-bit resolution.
- Low power consumption, with an energy efficient design suitable for various applications.
- Available heater mode, including condensation recovery for improved reliability.
Coolant Leak Detection Sensor
The Coolant Leak Detection Sensor spots liquid-cooling leaks early, preventing damage and costly repairs. Its highly sensitive detection capabilities make it ideally suited to industrial applications where dependable thermal management is essential.
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Key features of this sensor include:
- Precise detection, with a resistance specification of 510 Ω ±3 %.
- A wide operating range from -40 °C to 85 °C.
- Designed for seamless integration into battery systems, with a compact housing and simple installation process.
- RoHS compliance ensures adherence to relevant environmental and safety regulations.
Combination Pressure and Temperature Sensor
The dual-function sensor monitors pressure and temperature in a single, compact unit. The Combination Pressure and Temperature Sensor is great for battery energy storage systems, providing the real-time data required for essential thermal and pressure management.
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Key features of this sensor include:
- High accuracy, ensuring the precise readings necessary for efficient and stable system performance.
- A wide operational temperature range, from -40 °C to +160 °C.
- Heavy-duty construction, designed and manufactured to withstand high-pressure conditions and harsh environments.
- A compact, lightweight, space-saving design ensures simple and straightforward integration into battery storage systems (up to ~100 psi).
- Rapid response time, with real-time data enabling quick adjustments and informing preventive maintenance.
- Versatility and applicability, including cooling systems, thermal management, and industrial battery storage applications.
Telaire T3600 Series Hydrogen Detection Sensor
The fully calibrated Telaire T3600 Series hydrogen detection sensor has been designed for battery energy storage systems (BESS), most notably systems where battery-related gas events are a concern. This powerful sensor delivers a ratiometric analog output with a detection range of 0 to 16 % H2 gas concentrations.
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Key features of this sensor include:
- Rapid, high-sensitivity detection, preventing safety risks by quickly identifying potential hydrogen build-up.
- Reliable performance, ensuring dependable monitoring by maintaining accuracy over a wide temperature range.
- A compact design with minimal space requirements facilitates easy integration into BESS enclosures.
- Fully calibrated: Simplifies installation and reduces maintenance, supporting consistent and repeatable results.
Smarter Battery Energy Storage System Design Through Advanced Sensing
A well-optimized battery energy storage system design must consider more than energy storage: It must ensure that storage is continually efficient, safe, and reliable. Sensors able to detect temperature, humidity, off-gassing, and pressure collectively are key to creating a reliable safety net for contemporary battery storage systems.
Manufacturers can use the sensors described in this article to develop reliable storage systems that can meet today’s energy demands, while continuing to shape the future of battery energy storage system design.
Acknowledgments
Produced from materials originally authored by Amphenol Advanced Sensors.
This information has been sourced, reviewed and adapted from materials provided by Amphenol Advanced Sensors.
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