Transense to Supply Surface Acoustic Wave Sensing Tech for Cummins Heavy-Duty EV Motor

Why It Matters

Real‑time motor sensing unlocks data needed to optimize heavy‑duty EV drivetrains, accelerating commercialization of more efficient, reliable electric trucks.

Key Takeaways

• Transense provides SAWsense sensors for real-time torque, temperature data.
• DriveSense project runs 12 months, funded by APC R&D and UK DRIVE35.
• Embedded sensing aims to boost efficiency, durability of heavy‑duty EV motors.
• Cummins partners to scale smart electric drive manufacturing in the UK.
• SAW sensor data helps identify thermal stress and efficiency losses.

Pulse Analysis

Heavy‑duty electric trucks face a unique set of engineering challenges, especially around heat management and drivetrain efficiency. Traditional motor designs rely on external measurements, leaving a blind spot inside the rotating assembly where torque spikes and temperature gradients develop. Surface Acoustic Wave (SAW) sensors, like Transense’s SAWsense, embed directly in the motor housing, converting mechanical vibrations into precise electrical signals. This technology provides engineers with granular, real‑time data streams that can be fed into control algorithms, enabling dynamic adjustments to inverter timing, cooling strategies, and load distribution.

The DriveSense initiative, a joint effort between Cummins, Transense, and other UK partners, leverages this sensing capability to prototype a next‑generation electric motor. Backed by the Advanced Propulsion Center’s R&D program and the UK government’s DRIVE35 Innovation Fund, the 12‑month project targets scalable production in Britain. By integrating SAW sensors with advanced inverter designs, the team aims to demonstrate measurable gains in efficiency—potentially shaving several percentage points off energy consumption—while extending component life through proactive thermal management. The collaboration also serves as a testbed for data‑driven validation methods that could shorten development cycles for future electric powertrains.

If successful, the DriveSense model could reshape the heavy‑duty EV market by providing a replicable blueprint for sensor‑rich motors that deliver higher performance at lower total‑cost‑of‑ownership. Fleet operators would benefit from predictive maintenance insights, reducing downtime and warranty claims. Moreover, the UK’s manufacturing ecosystem stands to gain a competitive edge, positioning the region as a hub for intelligent propulsion technology. As regulators tighten emissions standards, such data‑centric motor solutions are likely to become a cornerstone of next‑generation commercial vehicle strategies.