Q&A: The Benefits of 48V Electrical Systems

As automakers increase safety features and efficiency, the electrical systems that power all this new technology must also evolve to ensure performance and user safety. 48V systems are at the heart of this evolution.

An increase in safety and infotainment features coupled with demand for range and energy efficiency in gas, hybrid, and electric vehicles has led the automotive industry to pursue the switch from 12V to 48V electrical systems. We spoke with Vasanth Krishna Sista, staff field application engineer at TE Connectivity, to learn more.

What specifically is driving the transition to 48V?

The growing power demands of modern vehicle applications have introduced significant challenges related to the weight and cost of wiring harnesses. More functions and newer advanced systems like steer-by-wire, ADAS, autonomous driving, infotainment, and connectivity systems, which require a lot more power, are making the traditional 12V architecture inefficient and unsustainable. Higher power demands lead to increased current, which requires thicker, heavier wires. Increasing the voltage level to 48V significantly reduces current draw for the same power, lightens the wiring harness, reduces cost, and improves overall system efficiency.

How does the change impact the vehicle’s electrical system, connectivity requirements, and the electricity demands to power the various automotive systems?

The low-voltage electrical system must incorporate suitable connectivity solutions to support 48V integration. Initially, power-intensive applications are expected to lead the shift to 48V systems. Over time, this transition is likely to align with the broader adoption of zonal architecture within the vehicles’ low-voltage systems, facilitating a more efficient and streamlined electrical framework. We can look at this in two ways. We can use the existing connector systems and depopulate some of the pins to accommodate the creepage and clearance required by the application to make it 48V compatible. This specifically applies for smaller terminal sizes due to tighter spacing between the terminals. Connectors with larger terminal sizes, in most cases, are already 48V compatible because they are big enough to prevent arcing.

OEMs are migrating to the newer zonal architecture where the ECUs within the vehicle are organized by zones, and not by function, and are managed by a zonal controller in the region. This enables simplified harness routing and reduced complexity for service.

What unique challenges arise in designing connectivity solutions for 48V systems compared to traditional 12V systems?

One of the key considerations is meeting the stricter clearance and creepage requirements necessitated by the higher voltage. These parameters ensure sufficient spacing between conductive components to prevent electrical shorts or insulation breakdown, which becomes more critical as voltage levels increase.

Additionally, special measures are often required at critical connection points to address the risk of arcing. At 48V, the potential for electrical arcing during connection or disconnection is more pronounced than with 12V systems, posing risks to component longevity and system safety. To mitigate this, advanced materials, precision engineering, and protective circuit designs are often employed. These solutions not only enhance durability and reliability but also help maintain system efficiency and safety under the demanding conditions of a 48V architecture.

To determine the creepage and clearance requirements, IEC 60664 specification requires six inputs: application voltage, pollution degree, altitude, material CTI (comparative tracking index), overvoltage category, and factor of safety. If we incorporate corrosion resistant materials, proper sealing for environmental protection, and minimize the risk of arcing, then being categorized as a 48V compatible product is sufficient. But more review is required for applications which have high current requirements. Touch safety features are necessary to address the safety concerns. Any voltage higher than 14V would lead to arcing, these could be reduced by design features such as first mate/last break, eCPA (electrical Connector Position Assurance), multiple contact points on the terminal for even distribution of the current, and reduction of localized heating.

What types of vehicles does this transition affect?

The transition to a 48V architecture is considered powertrain independent because it is not tied to a specific propulsion system. Unlike traditional systems that may need to adapt based on whether a vehicle is powered by an internal combustion engine (ICE), a fully electric setup, or hybrid, a 48V system can seamlessly integrate across all types of vehicles, regardless of the powertrain structure.

What does 48V mean for the future of hybrids and EVs?

48V serves as the foundation for the next generation of software-defined vehicles. This shift paves the way for improved efficiency, reduced weight, and the integration of more advanced features and functionalities, making vehicles smarter, more capable, and better optimized for the demands of modern technology. Rather than being an upgrade to the vehicle’s “muscles,” such as its propulsion system, it enhances the “neural system,” which enables faster and more efficient electrical power distribution. A 48V system allows higher voltage for robust power delivery. It is more efficient than 12V battery under heavy loads. The higher energy density of the 48V battery enables it to be packaged into smaller compartments for greater space savings. The low currents would allow for smaller connector terminals and reduce overall copper usage, resulting in tangible cost savings.

For hybrid vehicles, 48V systems offer a middle ground between standard 12V systems and the high-voltage systems typically found in full hybrids or electric vehicles. It helps power auxiliary systems, regenerative braking, and other electrified functions, all contributing to enhanced performance and energy savings without requiring a more complex electrical infrastructure.

Fully electric vehicles also benefit from the inclusion of a 48V subsystem. While their main propulsion system relies on high-voltage batteries, many onboard electronics, ADAS, and comfort features can operate on a 48V circuit. This reduces load on the main battery, extends range, and reduces wear, while offering a more efficient power delivery for secondary components.

TE Connectivity’s 48V-Ready Solutions.

How does TE Connectivity approach collaborating with automotive manufacturers to ensure seamless adoption of these innovations?

TE is working with leading EV manufacturers to develop 48V-ready mixed low voltage signal/power connectors while advocating for the standardization of 48V interfaces. Standardizing these interfaces fosters innovation, improves efficiency, and reduces complexity in automotive design by enabling seamless integration across systems and supporting advanced manufacturing processes like automation. It also simplifies the adoption of innovative solutions like flat wire or FFC/FPC cabling, which reduce weight, save space, and enhance design flexibility. Additionally, standardization streamlines component sourcing, reduces bill of materials (BOM) complexity, and enhances scalability, allowing automakers to implement 48V systems efficiently across various models. Through close collaboration with manufacturers, TE addresses design challenges, promotes innovation, and ensures the smooth adoption of 48V systems for future-ready vehicles.

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