Molex Releases Industry Report Exploring 48-volt System Evolution in Automotive Power
Transitioning from 12V to 48V electrical systems in vehicles brings a multitude of benefits and challenges to automakers. A new, informative report from Molex, "Rewiring the Road: Harnessing the Power of 48V," offers insights and advice for automotive engineers about what they need to know now to optimize system integration, reduce development costs and enhance vehicle performance and efficiency through 48V technology.
LISLE, IL – October 14, 2024
Molex, a global electronics leader and connectivity innovator, has issued a new report on the growing traction of 48-Volt electrical system technology, which is poised to fuel major improvements in vehicle performance, efficiency, functionality, and comfort. Molex’s report, Rewiring the Road: Harnessing the Power of 48V, addresses the momentum of 48V systems while offering pragmatic advice for automakers and product design engineers as they navigate the possibilities and challenges of transitioning from traditional 12V to 48V electrical systems.
“48V technology holds great promise, but the path forward requires industry-wide collaboration to overcome technical obstacles and establish industry standards,” said Scott Whicker, SVP and president, Transportation Innovative Solutions, Molex. “We are working with partners across the automotive ecosystem to accelerate 48V adoption. Together, we can optimize system integration, reduce development costs, and speed time to market for power system components and connectivity solutions, ensuring reliable and efficient power delivery.”
Unlocking New Vehicle Capabilities
By quadrupling system voltage, 48V technology advances automotive features and functionality, including electric turbocharging, regenerative braking, infotainment systems, and battery preconditioning for auxiliary charging. 48V systems boost the efficiency of electrically powered components for more responsive climate control, superior steering responsiveness, and precise engine temperature management. The higher current and voltage also increase power efficiencies in critical sensors, actuators, and control units, paving the way for fully autonomous driving.
Versatile 48V systems are adaptable to both traditional internal combustion engine (ICE) vehicles and fully electric models. Molex’s report highlights the demand for modular 48V platforms with flexible architectures tailored to various vehicle sizes, types, and power requirements. However, the higher voltage levels in 48V systems can lead to increased electromagnetic interference (EMI), presenting challenges related to shielding, wiring, and harness designs.
Caresoft Confirms Opportunities and Obstacles
Caresoft Global, a leader in automotive engineering analysis, has been examining the momentum of 48V technology. In a recent report, The Evolution of 48-Volt Architecture in Electric Vehicles, Caresoft reinforces major advantages and challenges of 48V systems, while tracking the progress of key EV manufacturers. Caresoft’s analysis underscores the impact of 48V technology on system efficiency, wiring complexity, and vehicle performance.
“The emergence of 48V architecture is a turning point for meeting critical environmental regulations and consumer demand,” said Terry Woychowski, president of Caresoft Global. “Forward-looking EV manufacturers are poised to increase 48V innovation by working closely with stakeholders across the EV ecosystem.”
Roadmap for 48V Success
Full-scale 48V adoption requires agile methodologies and collaboration to clear roadblocks, including upfront investments, integration into existing platforms, and compatibility with current electrical systems. Fine-tuning 48V battery performance is essential to boosting energy density, power output, and lifespan while reducing costs. Modular platforms with interchangeable components, such as electric motors and DC-DC converters, will offer building blocks for more efficient vehicle designs.
Advancing Connector Designs, Materials, and Manufacturing
48V systems require connectors with heightened performance and reliability, as well as advanced materials with superior electrical and thermal properties. Molex’s report highlights innovations in contact plating technologies to prevent corrosion, maintain conductivity, and extend connector lifespan. Design innovations, such as zonal architectures, improve power distribution, reduce wiring complexity, and boost system reliability.
Molex’s MX150 Mid-Voltage Connector System exemplifies the company’s commitment to addressing the evolving needs of the automotive industry. Capable of handling up to 60V, this connector system supports the use of smaller wire gauges to reduce weight and cost while maintaining high performance.
Learn more about the Rewiring the Road: Harnessing the Power of 48V report and other automotive connectivity solutions from Molex.
