Molex Report Highlights the Growing Impact of 48-Volt Electrical Systems in Vehicles
Molex’s report underscores the transformative potential of 48Volt electrical systems and the company’s efforts to drive innovation in the automotive sector.
Molex, a global leader in electronics and connectivity, has released a new report on the rising adoption of 48-Volt (48V) electrical systems, which are expected to significantly enhance vehicle performance, efficiency, and user experience. The report, titled “Rewiring the Road: Harnessing the Power of 48V,” provides insights into the technology’s potential while offering practical recommendations for automakers and engineers transitioning from 12V to 48V systems.
The Promise and Collaboration Required for 48V Adoption
Scott Whicker, Senior Vice President and President of Molex’s Transportation Innovative Solutions, emphasized the need for industry collaboration to address technical challenges and set standards for 48V systems. “The potential of 48V technology is immense, but overcoming obstacles will require collective efforts. Molex is actively working with partners across the automotive ecosystem to ensure efficient system integration, lower development costs, and faster delivery of reliable power components and connectivity solutions,” Whicker noted.
Unlocking New Capabilities with 48V Systems
With four times the voltage of traditional 12V systems, 48V technology enables more efficient and advanced features, such as electric turbocharging, regenerative braking, and infotainment systems. It also optimizes battery preconditioning for auxiliary charging, while improving climate control, steering responsiveness, and engine temperature management.
48V systems enhance power delivery for crucial automotive components, including sensors and actuators essential to Advanced Driver Assistance Systems (ADAS), paving the way for autonomous driving. These systems are adaptable to both internal combustion engine (ICE) vehicles and electric models, making them versatile across various vehicle types. However, the higher electromagnetic interference (EMI) associated with 48V systems presents challenges for shielding, wiring, and harness designs, particularly as higher voltage levels increase weight and cost.
Caresoft Global’s Perspective on 48V Systems
Caresoft Global, an expert in automotive engineering analysis, has highlighted the growing adoption of 48V technology as a means to improve fuel efficiency, reduce emissions, and enhance driving performance. In its recent study, “The Evolution of 48-Volt Architecture in Electric Vehicles,” Caresoft explores the benefits and challenges associated with 48V systems. Through detailed vehicle teardowns, the company has assessed how 48V architecture impacts system efficiency, wiring complexity, and overall vehicle performance.
Terry Woychowski, President of Caresoft Global, emphasized the importance of innovation, noting, “The shift toward 48V technology will be essential to meeting environmental standards and consumer expectations. Automakers committed to 48V solutions will need to collaborate closely with key stakeholders to overcome challenges and drive progress.”
Navigating the Road to 48V Adoption
Scaling up 48V systems requires flexible strategies and cross-industry cooperation to address challenges such as integration with existing vehicle platforms, managing upfront costs, and ensuring compatibility with current electrical systems. The fine-tuning of 48V battery performance—focusing on energy density, power output, and lifespan—will be crucial to reducing costs.
Modular platforms comprising electric motors, inverters, DC-DC converters, and batteries offer the building blocks for efficient vehicle designs. These interchangeable components will help manufacturers achieve greater efficiency while keeping production costs under control.
Improving Connectors and Power Distribution for 48V Systems
Since 48V systems demand enhanced connector reliability, Molex has focused on advanced contact plating technologies to prevent corrosion, ensure conductivity, and extend product lifespan. The report highlights zonal architectures as a key innovation for improving power distribution, minimizing wiring complexity, and enhancing system reliability.
Automated manufacturing processes are also crucial in ensuring consistent production quality and efficiency. Molex’s MX150 Mid-Voltage Connector System demonstrates the company’s dedication to meeting the evolving demands of 48V applications. Designed for compact, efficient assembly, the MX150 supports smaller wire gauges to reduce weight and cost without compromising performance. With a capacity to handle up to 60V, the system provides a reliable, robust solution for automotive wiring needs.
Conclusion
Molex’s report underscores the transformative potential of 48V electrical systems and the company’s efforts to drive innovation in the automotive sector. By collaborating with partners across the industry, Molex aims to accelerate the adoption of 48V technology, helping automakers achieve better performance, reduce costs, and support sustainability goals.
For further details, visit the Molex website.
