Feature: E-mobility
maintenance costs and downtime. Unlike other gas sensors, thermal conductivity-based HLD sensors do not require oxygen to provide effi cient and stable detection. HLD sensors can work in an inert or oxygen-defi cient atmosphere where other types of sensors, like catalytic beads, would fail. HLD sensors also have very fast response times, crucial for
safety in applications like automotive or fuel-cell systems. High sensitivity and accuracy allow these sensors to detect very small hydrogen leaks before they pose a safety risk. Fast leak detection enables quick corrective actions, preventing escalation of a hazardous situation. In addition, they are reliable and durable for tough industrial conditions, and support hydrogen safety standards and industry regulations. T eir simpler construction lowers their costs, allowing them to
be fabricated in high volume, with repeatable solid-state sensing elements. Overall, these benefi ts make them an economical option for widespread deployment. In gas leak detection, the key features TCDs off er are their
stability under varying conditions like shock and vibration, fast response times (under two seconds), high accuracy and high sensitivity; see the HLD-111-111-001 sensor (Figure 1) from Honeywell Sensing and Productivity Solutions, which uses advanced compensation algorithms to detect low hydrogen leakages. TCD-based HLD sensors are also less susceptible to
contamination from chemicals that might interfere with other sensor technologies. Unlike chemical sensors that degrade with
time, or catalytic sensors that are susceptible to poisoning from compounds like sulphur, HLD sensors don’t use reactive materials, leading to a much longer lifespan and greater reliability. Among their typical applications are fuel cell electric vehicles
(FCEVs), hydrogen refuelling stations, hydrogen generators, hydrogen storage and distribution, marine applications, and industrial applications including chemical processing, metal refi ning and semiconductor manufacturing. Like other electric vehicles, FCEVs use electricity to power
electric motors, which they generate with a fuel cell powered by hydrogen. Consequently, hydrogen leaks in the fuel system can pose a safety hazard and reduce vehicle effi ciency. By continuously monitoring the FCEV’s hydrogen tanks, pipelines and fuel cell stacks, the HLD sensors detect leaks to prevent dangerous situations and maintain hydrogen fuel effi ciency; see Figure 2. Likewise, hydrogen-powered EVs depend on high-pressure
storage tanks and refuelling stations, where leaks can present signifi cant safety risks. TCDs ensure that by continuously monitoring the refuelling infrastructure for leaks, EV makers can mitigate ignition risks. Concurrently placing these sensors across hydrogen dispensers and storage systems enhances operational effi ciency and safety, minimises downtime and builds consumer confi dence in hydrogen refuelling infrastructure. Similarly, hydrogen generators are essential for on-site
hydrogen production in industrial, medical and energy applications. For the safety of users around these generators, HLD sensors are placed in key locations to detect minimal leaks and
Figure 2: TCD-based HLD sensors deployed in fuel cell powered electric vehicles prevent hazardous situations such as leaks and maintain hydrogen fuel effi ciency
www.electronicsworld.co.uk June 2026 35
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