[Molex] Innovation in electric vehicle battery technology

12V power supplies have been the automotive industry standard since the 1950s; but to meet today's consumer demands, automakers are turning to 48V power supplies.

12V power supplies have been the automotive industry standard since the 1950s, making them the default in vehicle designs and components. The standard allows automakers to maintain simple electrical architectures and keep costs low even as vehicle capabilities and electrification continue to evolve. 

The 12V power mode has worked well in the past. However, as modern consumers have higher and higher expectations for vehicle performance and in-car experience, the 12V standard must keep pace with the times. The advent of emerging software-defined vehicles, the industry's use of mild hybrid architecture, and the introduction of stricter emissions regulations have made it increasingly necessary for the automotive industry to adopt 48V designs to meet consumer needs and regulatory requirements. 

Although there are some challenges in adopting 48V power supply, manufacturers focusing on electrical innovation research are preparing to develop more efficient systems based on this new standard. As vehicle design enters the future era of electrification, there are several key factors that the industry should fully understand and consider, including the drivers of the 48V standard, the benefits of using 48V power for automakers and consumers, and related challenges.

Factors driving the use of 48V power supplies

The automotive industry's move to more powerful power standards will not happen overnight, but a number of key electrical and consumer factors will drive automakers to adopt 48V power as the standard for mild hybrids and fully electric vehicles.

regulations to reduce emissions

Regulations requiring significant reductions in emissions for vehicle manufacturing have been implemented in many countries such as the United States, Europe, and China, prompting the industry to use mild hybrid architectures, such as integrated starter generators and 48V power networks, and to improve engine design efficiency; design engineers for this purpose Feel the pressure. A Molex survey of 824 design engineers found that 96% of respondents indicated that efforts are needed to comply with electrical-related regulatory requirements.

Stricter regulations regarding fuel economy are also driving the development of advanced technologies such as stop-start systems, advanced driver assistance systems (ADAS) and alternative propulsion solutions such as electric vehicles (EVs). These new technologies require higher power supply voltages, prompting the industry to use the 48V power supply standard.

Consumer preferences

Carbon-conscious buyers have a strong preference for hybrids, plug-in hybrid electric vehicles (PHEVs) and electric-enhanced vehicles. OEMs and component suppliers are actively responding to demand and are currently developing next-generation components and vehicles. This is consistent with the result that 74% of power supply design engineers surveyed by Molex ranked energy efficiency as their top priority.

Electric turbo

Electric turbocharging (E-turbo) features the use of an electric motor to spin a turbine and increase the amount of air intake into the engine, thereby enhancing engine performance. This turbocharging operation requires more power than a conventional 12V or 24V system powered turbocharging system. As more efficient and powerful electric turbocharging systems become standard, 48V power supplies will become mainstream.

space efficiency

Using a 48V architecture not only increases system voltage, it also requires changes to the electrical architecture of today's vehicles. Enabling feature-rich, higher-performance vehicles relies on using lighter, smaller components that offer the same electrical efficiency in a higher-density architecture. The 48V standard can provide consumers with a better infotainment experience and better realize vehicle integration functions.

Advantages of 48V power supply

Improving power and efficiency brings new opportunities to automakers and consumers. 48V power supplies can improve efficiency and add features, better helping automakers meet consumer interest in higher-tech and lower-emission vehicles.

48V engineering technology advantages

Reduced package size: 48V power supplies allow the production and use of smaller components that deliver the same level of electrical efficiency in higher-density architectures, making it easier to create feature-rich, high-performance vehicles without sacrificing space. Automotive designers can improve the overall performance of the vehicle by reducing the size of electrical systems but maintaining the same functionality.

Savings on production costs: Smaller components require less material, reducing production and sales costs while still meeting consumer demand. 48V systems are more efficient and can help reduce overall energy consumption by up to 30%.

Provide better functionality: Smaller component footprints allow designers to fit more functionality into a given space. Although the car is smaller, it can incorporate more advanced technologies such as wireless charging, powerful infotainment systems and advanced driver assistance systems. These enhancements improve the overall driving experience for consumers and increase the value and perceived quality of the vehicle. Additionally, the physical size of these components is reduced, allowing automakers to design sleeker, more aerodynamic vehicles with improved handling and stability.

Reduced emissions: 48V systems increase efficiency and reduce fuel consumption, carbon dioxide (CO2) and other pollutants emitted by internal combustion engine vehicles. Smaller components reduce vehicle weight and drag, further reducing emissions.

Improved fuel economy: Reducing engine load through enhanced electric capabilities helps automakers reduce the energy required to drive vehicles, resulting in lower fuel consumption and better fuel economy. The higher efficiency of the 48V system allows the vehicle to maintain excellent performance at higher speeds and be able to travel longer distances on a single tank or charge. 

Benefits of 48V power supply to consumers

Improved vehicle performance: Next-generation power solutions enhance the performance of existing engines, delivering more power and torque for improved acceleration. The electric motor delivers smoother torque at lower speeds to improve stability and comfort when cornering or driving on uneven surfaces. The 48V system also helps reduce load on the internal combustion engine, allowing it to operate more efficiently while improving performance and reducing fuel consumption. These lighter vehicles have a higher power-to-weight ratio, which improves overall performance.

Reduced vehicle costs: The 48V architecture uses smaller and fewer components, allowing for a more efficient production process. Manufacturers reduce the materials and labor required to produce vehicles, thereby lowering overall costs. For consumers, lighter, more fuel-efficient vehicles require less fuel and can lower the cost of vehicle ownership.

Improved handling: Electrically enhanced vehicles respond more quickly and accurately to inputs, making them easier to maneuver than other vehicles. The reduced weight allows the vehicle to accelerate faster while maintaining steering stability and enhancing driver control of the car. Lighter vehicles also make it easier for manufacturers to install advanced active safety systems (such as lane keep assist) without sacrificing overall performance, which improves the overall safety of the vehicle and enhances driver comfort on challenging roads. and terrain driving confidence.

Challenges in transitioning from 12V to 48V

12V power supply designs are already deeply embedded in automotive production, and the transition to 48V power supplies will be slower than expected. The speed of the transition depends in part on the component design changes required to meet the technical requirements of 48V systems, taking into account manufacturers' own production methods and existing infrastructure. The higher cost of 48V technology and its relative newness are factors that may further slow adoption as a strong business case is needed to drive large-scale technology change. 

Better battery management is key to the success of the 48V architecture. Without the right design, automakers face inefficiencies in power storage, increased costs, and potential safety risks from system instability. To ensure that existing power storage and battery capacity is fully utilized, automakers must invest in better hardware and software, including using predictive algorithms to adjust charging cycles based on usage needs and developing better ways to track battery health over time. Time changes. 

Advanced energy control systems are required to manage the voltage levels within each cell to prevent overcharging or undercharging of the battery pack. These measures require significant investment in research and development, but are necessary to create reliable 48V systems that meet modern driving conditions and potentially extreme environmental requirements.

Molex leads the development of 48V compatible components

As demand for electric vehicles has grown over the past 30 years, Molex has played a key role in serving the automotive industry. Molex is an early developer of solutions to support 48V applications, including connectors and power distribution systems that provide robust power management. Molex components help provide consistent connectivity and communication in 48V systems, ensuring reliable performance in any environment.

As an authorized distributor of Molex, Heilind can provide relevant product services and support to the market. In addition, Heilind also supplies products from many of the world's top manufacturers, covering 25 different component categories, and pays attention to all market segments and all of customers, are constantly seeking a broad product offering to cover all markets.