Molex's latest industry report explores the evolution of 48V systems, focusing on major changes in automotive power architecture

Molex has released a report exploring the rapid rise of 48V electrical system technology, which promises to dramatically improve vehicle performance, efficiency, functionality and comfort. Molex's Reimagining the Automotive Future: Introducing 48V Power Systems report explores the momentum of 48V technology and provides practical advice to automakers and product design engineers on the opportunities and challenges they may face as they transition from traditional 12V electrical systems to 48V electrical systems.

Scott Whicker, senior vice president and president of Molex's Connected Mobility Solutions business group, said: "48V technology has great promise, but to make it happen will require the cooperation of the entire industry to overcome technical barriers and establish industry standards. We are working with partners across the automotive ecosystem to accelerate adoption of 48V technology. Together, we can optimize system integration, reduce development costs, accelerate the time to market of power system components and connectivity solutions, and ensure reliable and efficient power delivery."

Unlock new vehicle features

48V technology significantly improves vehicle performance and functionality by increasing system voltage by a factor of four. These improvements include electric turbocharging, regenerative braking, infotainment systems, and temperature pre-regulation to assist battery charging. The 48V system not only improves the efficiency of the electric components, but also enables more sensitive climate control, superior steering response, and precise engine temperature management. In addition, the system enhances the power efficiency of critical sensors, actuators and control units to support advanced driver assistance systems (ADAS) and pave the way for fully autonomous driving.

The 48V multifunctional system is suitable for both conventional internal combustion engine (ICE) vehicles and electric vehicles. The Molex report points out that 48V systems have significant profitable growth potential in the current and future automotive markets and highlights the need for modular 48V platforms. These platforms have a flexible architecture that allows for 48V system customization based on vehicle size, type, and power requirements. However, the high voltage levels of 48V systems can lead to increased electromagnetic interference (EMI), making it more difficult to shield interference than low-voltage systems. At the same time, wiring and harness design is also critical, because greater current and higher voltage requirements bring challenges related to weight, space and cost.

Caresoft confirms the opportunities and challenges presented by 48V technology

As a leader in automotive engineering analytics, Caresoft Global continues to explore the significant benefits of 48V technology in improving fuel efficiency, reducing carbon emissions and enhancing the driving experience. In its latest report, The Evolution of 48V Architecture in Electric Vehicles, Caresoft highlights the core competencies and challenges of 48V technology while illustrating the latest developments among mainstream electric vehicle manufacturers. With its sophisticated vehicle dismantling technology, Caresoft has performed a detailed dismantling and analysis of 48V models to show how the technology affects system efficiency, cabling complexity and vehicle performance.

Terry Woychowski, President of Caresoft Global, said: "The rise of 48V architectures marks a major turning point in meeting key environmental regulations and consumer needs. Forward-thinking EV manufacturers should drive innovation in 48V technology and lower the barrier to success by working closely with core stakeholders within the EV ecosystem."

A roadmap for 48V technology success

Achieving widespread adoption of 48V technology requires a flexible strategy and industry collaboration to overcome challenges such as initial investment, technology integration, and compatibility with existing electrical systems and safety features. Precisely optimizing 48V battery performance is critical to improving energy density, power output, service life, and cost reduction. A modular platform with interchangeable components such as electric motors, inverters, DC-DC converters and batteries lays the foundation for more efficient and economical vehicle design.

Advance connector design, materials and manufacturing technology

48V electrical systems require the industry to improve the performance and reliability of connectors and use advanced materials with superior electrical and thermal properties. The Molex report provides insights on improved contact coating technology aimed at preventing corrosion, maintaining optimal electrical conductivity and extending the service life of connectors. Design innovations such as regional architecture are critical to optimizing power distribution, reducing cabling complexity, and improving system reliability. Precision manufacturing of automated assembly processes also helps ensure consistent production quality and efficiency.

The MX150 medium voltage connector family from Molex demonstrates the company's commitment to meet the changing needs of the automotive industry. Designed for efficient assembly and reduced package size, the MX150 provides a robust and reliable solution for 48V cabling applications. The series is able to withstand voltages up to 60V, thus allowing the use of thinner wires, which reduces the weight of the vehicle and reduces costs, while maintaining high performance.