connectors. It then presents suitable solutions from Molex and describes how these solutions may be applied in practical scenarios. The benefits of 48 V automotive architectures Automakers can implement mild hybrid systems that recuperate energy during braking and coasting by moving to mid-voltage architectures. They can also deploy enhanced start-stop systems that reduce fuel consumption while city driving and in traffic jams. Additionally, because the higher voltage allows the use of lighter, smaller-gauge wires to deliver the same power at a lower current, 48 V systems reduce vehicle weight. All these factors translate to significant fuel savings, particularly in smaller vehicles. Higher-power wiring harnesses are also needed to accommodate the electrification of components such as power steering, air conditioning, and the adoption of advanced driver assistance systems (ADAS), such as adaptive cruise control and lane- keeping assist. Transitioning to a 48 V architecture meets this need without the costs and complexities associated with the high-voltage systems (i.e., 400 V and beyond) used in full hybrid electric vehicles (HEVs) and battery electric vehicles (BEVs).
The 48 V architecture also serves as a bridge to greater vehicle electrification, allowing gradual integration of hybrid technologies without a complete electrical overhaul. These mid-voltage systems will remain valuable even in fully electric vehicles, as evidenced by their incorporation into designs like the Cybertruck. Cost considerations for 48 V connectors The question of which electrical connection system should be used for 48 V architectures can be answered by looking at the technical challenges arising from the increased voltage. Adopting the high-voltage connectors developed for use in electric and hybrid vehicles is technically feasible, but cost and package-space considerations make it inadvisable. In contrast, adapting 12 V connectors for mid-voltage architectures is an attractive cost and size proposition. It is worth noting that not all vehicle systems will switch to 48 V. Some smaller devices that consume less power will stay at 12 V. Therefore, it is useful to have consistent connectors across 12 V and 48 V systems to simplify tooling and technician training.
operational, regulatory, and safety requirements of mid-voltage automotive architectures before choosing from an appropriate supplier’s selection. This article reviews the benefits of 48 V architectures and outlines the challenges of selecting appropriate
Molex’s MX150 Mid-Voltage Connector System (Figure
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