48V Automotive Electrical Architecture

Q. What is a 48V automotive electrical architecture?
A. A 48V automotive electrical architecture is a low-voltage electrical network designed to support higher vehicle power demands at lower current levels than traditional 12V systems. It can support high-power vehicle functions while operating alongside other voltage domains within the vehicle.

Q. Why are automakers adopting 48V systems?
A. 48V systems help support growing power demands by delivering the same power at lower current than 12V systems. Lower current can enable smaller conductor sizes, heat losses, decrease harness weight, and help address power-delivery constraints.

Q. What are the benefits of a 48V electrical system compared with a 12V system?
A. Compared with a traditional 12V system, a 48V electrical system can deliver the same amount of power at significantly lower current. Lower current can enable smaller conductor sizes, helping reduce copper usage, wiring-harness weight, packaging requirements and resistive power losses. A 48V architecture can also support growing electrical loads and higher-power functions while working along side existing 12V and high-voltage vehicle networks.

Q. How does 48V reduce wiring weight and power loss?
A. For the same power requirement, increasing voltage from 12V to 48V reduces current to one-quarter. This lower current can enable smaller conductor cross-sections, helping reduce copper usage, harness weight, and packaging requirements. Theoretically, for the same resistance, resistive power loss can be reduced to one-sixteenth.

Q. Are 48V systems only used in electric vehicles?
A. No. 48V architectures can be used across internal combustion engine (ICE), hybrid, and battery-electric vehicles to support a range of functions, including auxiliary systems, chassis systems, comfort features, and vehicle electronics.

Q. Can 12V and 48V systems coexist in one vehicle?
A. Yes. A DC/DC converter can supply traditional 12V components while higher-power functions operate on the 48V network, enabling both voltage domains to coexist within the vehicle.

Q. How does 48V support zonal vehicle architectures?
A. A 48V power backbone can efficiently distribute power to zone controllers and other higher-power loads. Local DC/DC conversion can then supply nearby 12V devices, helping reduce long 12V cable runs, simplify wiring, and reduce harness weight.

Q. Which automotive applications benefit from 48V?
A. 48V can support a wide range of higher-power vehicle functions, including electric power steering, active suspension and chassis systems, cooling fans, pumps, PTC heaters, air-conditioning compressors, e-turbos, and motor generators.

Q. Why do 48V connectors require special design considerations?
A. 48V applications require careful consideration of creepage and clearance distances, current-carrying capacity, wire size, environmental sealing, and secure locking. Connector designs may also need to address electrical arcing during mating or unmating under load, depending on the application. Click here to learn more about evaluating connectors for 48V applications and TE’s 48V evaluation strategy.

Q. Can existing 12V connectors be used in 48V systems?
A. Some existing connector systems may be suitable for 48V applications, but compatibility should not be assumed. Each connector must be evaluated against the application’s voltage, current, creepage and clearance, environmental, and other performance requirements. Click here to learn more about evaluating connectors for 48V applications and TE’s 48V evaluation strategy.

Q. How is 48V different from 400V or 800V EV systems?
A. 400V and 800V systems are high-voltage networks primarily used for EV traction and other high-power functions. A 48V network operates at a much lower voltage and can support a range of vehicle functions, including power distribution, chassis, auxiliary, and electronic systems. Both voltage domains can coexist within the same vehicle.

Q. What is the Low-Voltage Connector Standard (LVCS)?
A. TE’s Low-Voltage Connector Series (LVCS) is a portfolio of connector interfaces designed to support evolving low-voltage vehicle electrical architectures, including 48V systems. The series includes 13 interfaces incorporating 0.64 mm and 2.8 mm terminal technologies in discrete and mixed configurations to address a broad range of automotive connectivity requirements.

Q. What does “48V-ready” mean for a TE connector?
A. “48V-ready” means that TE has evaluated the connector for suitability in 48V applications. The evaluation considers operation at 60V, along with factors such as creepage and clearance distances, pollution degree, insulating material properties, altitude, and applicable application-specific requirements.

Q. Which TE connector families support 48V applications?
A. TE offers a broad portfolio of connectivity solutions for 48V applications, including the LVCS Series and select products from the MCON, AMP MCP, and Heavy Duty Sealed Connector families, as well as higher-power connectivity solutions for batteries, powertrain systems, and other high-power vehicle loads.

Q. What are the key features of TE’s MCON connectors for 48V systems? 
A. Select MCON connectors support 48V applications with a robust two-piece contact design that separates electrical and mechanical functions. Sealed options provide reliable performance in demanding automotive environments, including applications exposed to vibration, mechanical stress, moisture, and other environmental conditions.

Q. What are the key features of TE’s AMP MCP connectors for 48V systems?
A. Select AMP MCP connectors support 48V applications with a robust two-piece contact design that separates electrical and mechanical functions, enabling high current capacity, reliable performance, and strong vibration resistance. Sealed and unsealed options support flexible wire-to-wire and wire-to-board connectivity across a range of 48V applications.

Q. What do TE’s Heavy Duty Sealed connectors offer? 
A. Select Heavy Duty Sealed Connectors support 48V applications with environmental sealing, multiple AMP MCP contact sizes, and a robust slide-lock mating system. These features help provide secure, reliable connectivity in demanding automotive environments.