37
tures and improve fuel efficiency, while reducing carbon emissions. Early on, 48V was predicted to revolutionize the automotive industry and rapidly render 12V systems obsolete. Over time, however, the practical challenges and economic re- alities of transitioning to 48V have shifted thinking from a total replacement to a complementary coexistence between 48V and 12V systems. Evolving 48V value proposition Vehicles have hundreds of 12V components spanning interior lights, window motors, sensors and control units, among many other systems. The sheer cost and engineering effort to redesign all these components for 48V would be astronomical and illogical given the impact on engineering, supply chain, manufacturing, testing, and validation. Instead, automakers have looked for opportunities to introduce hybrid functionality without the higher cost and complexity of full hybrid or battery electric vehicles. In Molex’s industry report exploring the evolution of 48V systems , rising adoption of mild-hybrid electric vehicles (MHEVs) is a crucial catalyst for more widespread use. MHEVs inherently rely on dual-voltage 12V and 48V systems, with a DC/DC converter as the intermediary between 48V and 12V systems to achieve incremental improvements. Figure 1 depicts the core components of a 48V system, en- compassing the battery, electric motor, power electronics, power distribution system and controller. A 12V battery and electrical distribution center play important roles in supporting low-power features and functionality. The DC/ DC converter and hybrid controller also are vital to ensuring seamless interaction between 48V and 12V systems.
MHEVs often rely on 48V systems to add capabilities to existing internal combustion engines, such as integrated starter-generators, electric turbochargers, and active sus- pensions. In doing so, they also boost fuel economy and reduce emissions. As a result, MHEVs have carved out a significant niche in the automotive industry, with the seg- ment projected to reach $290 billion by 2032 . MHEV growth is stimulating development and mass produc- tion of 48V components, including 48V batteries, inverters, DC/DC converters, as well as modular, high-density connec- tors capable of packing more connections into a smaller footprint. By quadrupling voltage from 12V to 48V, the same amount of power can be delivered with one-quarter of the current, producing massive efficiency gains. Lower current also allows replacing heavy copper wires with thinner, lighter wiring, reducing weight by up to 85% for individual high-current power cables. Thinner wires are more flexible and require less space, making it possible to reduce overall wiring-harness volume and simplify assembly. Lower current also means less heat generated within the components themselves, which lowers thermal management concerns and boosts system efficien - cy. In addition, smaller wires make routing much easier while the use of compact connectors and terminals contributes to the cascading effect of space, weight, and cost savings. 48V systems can realize their full potential when combined with zonal electrical architecture, which slashes the distance that data and power cables must travel to connect to local gateways serving as processing hubs and power distribu- tion modules. Furthermore, zonal architecture dramatically decreases the number of electronic control units (ECUs), which reduces wire length, weight, and cost. In zonal layouts, electric controllers are decentralized to modular zones at
Powered by FlippingBook