Shunts by ISABELLENHÜTTE – High-Precision Shunt Solutions

Precision and Traceability in Every Shunt

ISABELLENHÜTTE’s analog shunt solutions offer precision and reliability, making them the ideal choice for accurate current measurement in demanding applications. Each shunt comes with aunique serial number and manufacturing date, ensuring full traceability. Additionally, the measured resistance values and nominal Temperature Coefficient of Resistance (TCR) are stored inthe DMC-code, providing essential data for precise performance tracking.

Integrated Temperature Sensing and Optimized Signal Pickup

Another key advantage of this design is the integration of NTCs (Negative Temperature Coefficient Thermistors) on the PCB, allowing real-time temperature monitoring and compensation for temperature-related resistance variations. As a result, the analog sensor efficiently supports two critical battery management system (BMS) functions: current measurement (CSM) and temperature measurement (TMP).

By embedding the PCB directly onto the shunt, the analog shunt ensures precise and stable signal transmission, reducing external interference and minimizing additional assembly steps. A dedicated connector facilitates the extraction of voltage and temperature data, seamlessly transmitting analog signals to the customer's higher-level
control system.

The user gets a very good measurement signal because the PCB is placed exactly where the temperature coefficient is most favorable. If the user chooses his own contacting, this could be at a point where the TCR cannot be measured optimally, so that the measurement result is negatively influenced. On the other hand, with the PCB applied directly to the edge of the resistance material, the best possible pickup of the measurement signal is guaranteed.

Design Flexibility and Application Versatility

The analog sensor with PCB also promises greater flexibility in terms of installation space: The system does not need to be designed in a special way so that the shunt and separate PCB are as close to each other as possible. It should be noted that the lead to the higher-level PCB can act like an antenna and thus interference can be received. However, this problem can be solved with a twisted or shielded lead.

The high accuracy, temperature compensation capabilities, and seamless integration into battery management systems (BMS) make them ideal for both automotive and industrial energy applications (Figure 1: BSN-Product Picture, Figure 2: BSL tinned-Product Picture).

Furthermore, ISABELLENHÜTTE presented the new BSX Shunt, with a continuous load up to 1340A (Figure 3: Product Picture).

Automotive & E-Mobility Applications

Analog shunts play a crucial role in Battery Disconnection Units (BDU) and Battery Junction Boxes (BJB), ensuring accurate current sensing and thermal monitoring in various electric vehicle platforms, including:

• Passenger Cars – supporting efficient energy distribution in electric and hybrid vehicles
• Agricultural EVs – used in electric tractors, automated farm machinery, and other off-road vehicles, where durability and precision are key
• Trucks & Busses – ensuring stable and safe power management in commercial electric fleets
• Two- and Three-Wheelers – providing compact and lightweight current sensing solutions for electric motorcycles, scooters, and rickshaws
• Excavators & Mining Equipment – used in heavy-duty electric and hybrid mining machinery, where reliable current measurement is essential for high power loads
• Alternative Mobility Solutions – including snowmobiles, electric wheelchairs, trains, and other specialized electric transport solutions that require highly accurate current measurement and monitoring

Energy Storage Systems Applications

• Battery Monitoring Units (BMU) & Pack Monitoring – ensuring precise energy management in large-scale battery packs
• Stationary Energy Storage Systems – supporting grid storage, renewable energy systems, and backup power applications by providing real-time current monitoring
• Mobile Energy Storage Systems – used in portable and modular battery storage solutions, ensuring safe and efficient power distribution

Industrial & Power Electronics Applications

• Industrial Inverters – Though dominated by hall-effect sensors, analog shunts are used for high-accuracy measurements in industrial power conversion applications.
• Phase Current Measurement – enabling accurate phase current sensing in electric motor drives and inverters.
• Sum Current Measurement – supporting multi-phase power applications by providing aggregated current sensing across multiple circuits

Full TCR Measurement

What sets these shunts apart is the 100% TCR measurement performed on every unit – unlike many competitors that only measure TCR at the batch level. This guarantees high total tolerance over the product’s lifetime, even under varying operational conditions, as validated by customerspecific mission profiles (Figure 4: Example Temperature & Resistance Change).

By integrating seamlessly with standalone shunts or active Current Shunt Monitor (CSM) solutions, these sensors provide an accurate and complete analog measurement package (Table 1: Analog Sensors).

Explaining the TCR and How to Read From the DMC-Code

Each ISABELLENHÜTTE analog shunt features a unique polynomial stored in its Data Matrix Code (DMC), representing precise, component-specific characteristics. Unlike competitors who rely on batch-level approximations, ISABELLENHÜTTE ensures that every individual shunt undergoes End-of-Line (EOL) testing, where its Temperature
Coefficient of Resistance (TCR) is measured and laser-etched directly onto the component.

The TCR defines how a material’s resistance changes with temperature, and every alloy inherently has its own TCR value. In analog sensors, this value is influenced by both the material composition (alloy and copper) and the precise placement of sensing traces (Table 2: Lookup Table, Figure 5: Rchange).

Your Contact Person

Don’t hesitate to contact Matteo Nervo for further information about analog shunts.