How is the electrification of cars driving new vehicle concepts forward? An overview of current architecture, high-voltage systems, and components.DigiKey
Electrification replaces mechanical systems with electrical modules - from power steering to cooling pumps. New vehicle architectures, 48-V technologies, and intelligent components are driving this change across the entire mobility industry.
The development of the automotive industry through electrification - replacing traditional mechanically driven systems with electrical components and systems - is fundamentally changing the design of today's vehicles, ranging from internal combustion engines to mild hybrids and fully electric architectures.
Just as systems have evolved from carburettors and simple exhaust systems to precision injectors, emission control systems, and drive and brake control systems, similar advances have been made in electrification with new architectures, electric motor components, battery packs, and advanced power electronics. Taken together, these advances are forcing a rethink of how vehicles are designed and driven to achieve maximum efficiency, reliability, and safety.
Experts from two industry-leading electronics companies - Matt McWhinney and Kirk Ulery, Business Development Manager at Molex and Shawn Luke, Technical Marketing Manager at DigiKey - shed light on the current state of the electrification movement and the key considerations for the future of the automotive industry.
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Market trends in hybrid, mild hybrid, and electric vehicles
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While the much-discussed demand for electric and hybrid vehicles continues to rise, the sales of new electric vehicles have slowed in recent months due to many factors, including the market and public policy. Industry experts cite costs and limited charging infrastructure as two main reasons.
"We have repeatedly had issues with electrification," said Ulery. "When you drive more than 100 kilometres at a stretch, you know that the charging infrastructure needs to be addressed."
Hybrid vehicles, on the other hand, are surpassing the sales of electric vehicles. According to data from Edmunds, hybrid purchases saw the strongest increase in 2023, from more than 750,000 sales in 2022 to over 1 million sales in 2023.
Another emerging category is the mild hybrid, which uses a battery-powered electric motor to complement the petrol or diesel engine. Most mild hybrids operate with a 48-volt electrical system, which has a higher voltage than the electrical system of a conventional internal combustion engine vehicle. The 48-volt system powers components that do not rely on the engine, enabling greater operational efficiency.
Despite the rapid pace of innovation in automotive engineering, petrol-powered vehicles still dominate the roads. According to a study by Edmunds, 82% of new vehicles sold today are petrol-powered. However, electrification is in full swing, from traditional vehicles to the most advanced high-tech electric models.
Electrification under the bonnet
Ulery notes: “One constant we see is the increasing electrification - mechanical systems are being electrified in all vehicles for many reasons, particularly to increase efficiency.”
An example of this is stop-start technology, which shuts off the engine when a vehicle stops and automatically restarts it when the driver releases the brake or presses the accelerator. While this feature can put additional strain on some components, it aims to improve fuel efficiency and reduce greenhouse gas emissions.
Further examples of electrification under the bonnet include radiator fans, power steering, HVAC systems, and cooling pumps. All these systems were previously driven by belts from an internal combustion engine (ICE). Electric water pumps replace mechanical radiator pumps to achieve more efficient performance, and precise control with electric cooling can extend the lifespan of these parts. With enhanced battery management, they also circulate coolant in the vehicle to regulate the temperature of the battery pack, electric motors, and power electronics.
By switching to electrically operated modules, such as power steering pumps, the system is no longer dependent on the engine, reducing parasitic loads and making more horsepower available. Therefore, car manufacturers can install smaller engines in some vehicles while maintaining the same driving performance, achieving efficiency advantages and emitting fewer emissions.
“Electrification has opened the door to innovative new vehicle designs,” says Luke. Without the need to accommodate a traditional combustion engine, car manufacturers have more flexibility in distributing batteries and charging ports, the ability to increase space for passengers or cargo, and much more.
Overall, the electrification movement is replacing traditional mechanical systems with electrically controlled precision systems that can be more efficient. Combined with advances in software control, modern vehicles are cleaner and more energy-efficient, offering performance and sustainability for both passenger and commercial vehicle drivers.
Advancement of Vehicle Battery: 48 V
In the last decade, vehicle manufacturers have moved from 12-volt batteries to higher voltages like 24-volt batteries (especially for commercial vehicles) and now to 48-volt batteries to increase power capability, reduce vehicle weight, improve acceleration, and achieve fuel savings.
Legislation in Europe has laid the foundation for emissions reduction in newly built vehicles. A combination of regulatory and market forces is the reason for the increasing shift to mild hybrid architectures with integrated starter generators. 48 V is not only on the rise in mild hybrids but is also likely to be used in further combustion platforms.
The switch to a 48 V architecture involves more than just increasing the system voltage. It also requires a change in the electrical foundation. High-performance vehicles with many features rely on lighter and smaller components that offer the same electrical efficiency as a higher density model.
Ulery says: "The commonality is that both the 12V and 48V systems transfer traditional mechanical functions from a serpentine belt to a series of electric motors." He cited an example of a heavy pickup truck that uses mechanical energy for its power steering. In many vehicles, this function is increasingly being electrified. "The energy required for power steering comes at the expense of engine performance. By shifting the power steering to a separate electrical system, the driver can gain more power through the drivetrain."
The transition of the automotive industry to high-voltage systems is happening gradually, as it has significant impacts on the design and manufacturing process. The transition occurs at each manufacturer according to a different schedule, depending on the products, technical maturity, and customer requirements they serve. Furthermore, all are bound by standards and design practices related to the technologies they use, such as:
ISO 21780 includes requirements and tests for electrical and electronic components in road vehicles with an electrical system operating at a nominal voltage of 48 V.
The VDA recommendation is issued and maintained by the ZVEI - Central Association of the Electrical and Electronics Industry. It covers a wide range of specifications and testing requirements for electrical and electronic components in motor vehicles to develop the 48V power supply.
Compliance with the standard for intelligent battery management is a crucial factor for the success of the 48V architecture. With the right design process, automotive manufacturers can avoid inefficient energy storage, higher costs, and potential safety risks for drivers.
A glowing car battery icon floating in a digital environment, surrounded by data streams representing electric vehicle technology, online diagnostics, and energy analytics.
Requirements for Connection Technology and Connector Systems
As vehicles require more power than ever before to support increasingly demanding electrical functions, a reliable connector design for 48V systems depends on several fundamental factors to meet the performance and safety standards of vehicles.
McWhinney says: "The electronics and the infrastructure - the connections to support the vehicle - are essential for safety."
Since 48-volt systems operate at a higher voltage (than 12 V), connectors and electrical systems must be built from robust materials and with appropriate insulation to ensure safe and reliable performance. This becomes even more important when the voltage is higher than 48 V.
Failures in the connections can lead to vehicle system malfunctions or safety risks. To avoid connection failures, connectors should have locking mechanisms and strain reliefs and be regularly checked and maintained.
“Safety and monitoring of the electrical system are more important today than ever,” says McWhinney.
Maintaining signal quality is extremely important for applications with higher voltages. Poor signal integrity can lead to malfunctions, so connectors must minimise signal loss and interference through shielded cables, as well as proper grounding and strategic placement. Considering these factors requires innovation and expertise, and this is where advanced connection solutions come into play.
“It feels like a given, but the importance of interplay in automotive design is underestimated.”
Molex connectors in a Cybertruck. As 48-volt systems operate at a higher voltage (than 12 V), connectors and electrical systems must be built from robust materials and with appropriate insulation.DigiKey
Keeping up with the change and certification of parts
Meeting safety requirements is a top priority, but McWhinney points out that an additional challenge lies in the constantly changing requirements for vehicle electrics, forcing manufacturers to keep up and constantly revise connectors and other components.
Manufacturers can refer to the LV214 standards at any time to track performance requirements and carefully examine and certify approved components for safe use in the automotive industry.
Components that meet LV214 or similar qualifications are generally high-quality, robust, and reliable parts that can be used in road traffic without performance loss. For example, the MX150 connector series from Molex offers components designed for vehicles with harsh environmental conditions and are resistant to extreme temperatures, vibrations, and moisture.
Luke notes: "With more opportunities for innovation in vehicle design, more and more vehicle manufacturers are turning to electrification. Due to the hyper-fast innovation cycle, there are few standard platforms in this area. However, this greater variety offers consumers more style and customization options, and the costs of vehicles are likely to decrease with technological advancement and increased production."
Dr. Thomas Kaiser from Bosch and Till Beck from Kromberg & Schubert spoke at the 12th International On-Board Network Congress about "Lean HV Connector: Improved Performance by Close Collaboration along the Supply Chain."
Reliability and Durability in the Commercial Vehicle Sector
A lot has already been said about passenger cars, but everything discussed in this article has been happening in the commercial vehicle sector for much longer. Commercial vehicles quickly switched from 12- to 24-volt systems to power diesel and some electrical systems, allowing them to have smaller starters in the past. There is also a long tradition of electric air conditioning in commercial vehicles, especially in buses, construction and agricultural vehicles, and heavy-duty trucks, to name just a few.
Commercial vehicles are generally designed to help their owner/operator earn money and therefore need to function reliably. The reliability requirements over a lifecycle are usually higher than for passenger cars, requiring additional sealing and robustness.
Commercial vehicles have quickly switched from 12-volt to 24-volt systems.scanrail, DigiKey
Regardless of whether it is the development of passenger or commercial vehicles, engineers today must consider numerous complex, energy-intensive systems and functions that not only meet the demands of consumers and businesses but are also highly efficient, durable, and safe. Fortunately, technology providers are rising to the challenge of developing technology to solve these innovation problems.
As automotive engineers reshape the future of transportation, suppliers like Molex and distributors like DigiKey are on board, providing high-quality components, services, and expertise to enable this transformation.
