Molex explores 48V systems in new industry report | Automotive Testing Technology International

Oct 26, 2024

Electronics specialist Molex has released a new report on the growing traction of 48V electrical system technology, which is poised to lead major improvements in vehicle performance, efficiency, functionality and comfort.

Molex’s Rewiring the Road: Harnessing the Power of 48V addresses 48V momentum while offering advice for auto makers and product design engineers as they navigate the challenges of transitioning from traditional 12V to 48V electrical systems.

Scott Whicker, SVP and president, transportation innovative solutions, Molex, said, “48V technology holds great promise, but the path forward requires industry-wide collaboration to overcome technical obstacles and establish industry standards.”

Switching to 48V technology advances automotive features and functionality, including electric turbocharging, regenerative braking, infotainment systems and battery preconditioning for auxiliary charging. It also boosts the efficiency of electrically powered components. The delivery of higher current and voltage also increases power efficiencies in the critical sensors, actuators and control units needed for ADAS while also supporting fully autonomous driving.

48V systems are adaptable to both traditional internal combustion engine (ICE) vehicles and fully electric models. However, higher voltage levels in 48V systems can lead to increased electromagnetic interference (EMI), making it challenging to shield against interference than lower voltage systems. Higher current and voltage requirements introduce challenges pertaining to wiring, weight, space and cost.

The journey to full-scale 48V adoption requires agile methodologies and industry collaboration to clear roadblocks, including upfront investments in 48V components, integration into existing platforms and compatibility with current systems.

The need to fine-tune 48V battery performance is essential to improve energy density, power output and lifespan while decreasing costs. 48V electrical systems require heightened connector performance and reliability, as well as advanced materials with superior electrical and thermal properties. Molex’s report shares insights on improvements in contact plating technologies to prevent corrosion, maintain optimal conductivity and extend connector lifespan.

The report also highlights Molex’s ongoing support for the development of vehicles with 48V systems. The Molex MX150 mid-voltage connector system exemplifies the company’s commitment to addressing the evolving needs of the automotive industry. Engineered for efficient assembly and reduced package size, the MX150 delivers a “robust, reliable solution for 48V wiring applications”, the company says.