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Published by:
ZVEI - German Electrical and Electronic
Manufacturers’ Association
Electronic Components and Systems and
PCB and Electronic Systems Divisions
Lyoner Strasse 9
60528 Frankfurt am Main, Germany
Responsible:
Hans-Martin Fischer, ZVEI
Dr. Reiner Korthauer, ZVEI
Authors:
Jürgen Bilo, Continental
Dr. Heinz-Georg Burghoff, Horegulus Consulting
Humberto dos Santos, TDK Europe
Jürgen Engbring, Leoni Bordnetz Systeme
Edmund Erich, Delphi
Peter Gresch, OptE GP Consulting
Frank Harrmann, Leoni Kabel
Dr. Thomas Heckenberger, Mahle Behr
Norbert Hees, Kostal
Istvan Hegedüs-Bite, ZF Friedrichshafen
Dr. Helmut Kalb, Leoni Kabel
Dr. Matthias Kriegel-Gemmecke, NSG
Dr. Christian Kuper, Johnson Controls
Antonio Leone, Freescale
Dr. Marc Nalbach, Hella
Bernd Piller, Continental
Hans Rechberger, Webasto
Norbert Schnocks, Continental
Richard Schöttle, Robert Bosch
Hans-Joachim Schröder, Brose
Ulrike Sinner, Valeo
Waldemar Stabroth, TE Connectivity
Joachim Weitzel, Infineon
Michael Günther Zeyen, vancom
April 2016
While every care has been taken to ensure the accuracy of this document,
ZVEI assumes no liability for the content. All rights reserved. This applies in
particular to the storage, reproduction, distribution and translation of this
publication.
Table of Contents
1. Introduction 4
1.1 CO2-limits: the discussion and results 5
1.2 A look back at the debate on 42-volt systems in 2000 6
1.3 The market for hybrids – issues and trends 7
1.4 Economic context 9
1.5 VDA Recommendation 320 10
1.6 Additional technical challenges 11
2. Architectures 15
2.1 Powertrain 15
2.2 Types of electrical system topologies 17
3. Components 19
3.1 Generators and motors 19
3.2 Heaters and additional heating systems 20
3.3 Air-conditioning compressors 21
3.4 Pumps 22
3.5 Windshield defrosters 22
3.6 Chassis functions 24
3.7 Fan motors 25
3.8 Connecting systems 26
3.9 Wiring harnesses 27
3.10 Inverters 28
3.11 DC/DC converters 28
3.12 Energy and battery management 29
3.13 Active electronic components 30
3.14 Passive components 33
5. List of Abbreviations 37
3
1. Introduction
The automotive industry can only barely con- The new 48-volt voltage level (figure 1) opens
tinue or no longer meet the challenge pre- up more cost-effective opportunities for
sented by the CO2 targets defined by the Euro- hybridisation. The development of these mul-
pean Commission purely by improving standard tiple-voltage architectures in vehicles requires
internal combustion engine technology. Alter- detailed investigation at both the systems and
native drive concepts that make it possible to components levels.
drastically reduce average fleet CO2 emissions
will need to be deployed. As part of this process, a third voltage level of
48 volt has been defined to supplement the
While today’s hybrid vehicles meet this techni- voltage levels of 12/24 volt and high-voltage (>
cal criterion, they are not yet available at suf- 60 volts). The primary purpose of this new volt-
ficiently attractive price points. This is, above age level is to reduce CO2 emissions by means
all, due to the high cost of meeting the safety of recuperation and start-stop features and to
requirements that arise as a consequence of the power electrical components classed as high-
electric drive function in these vehicles being power loads (such as air-conditioning compres-
realized using voltages in excess of 60 volts (the sors, electrical heaters, pumps and steering
maximum permissible contact voltage). drives). Over and above this, the deployment of
48-volt technology providing additional torque
Architecture: enables more dynamic handling and perfor-
mance (a “boost” effect).
DC / DC Inverter
12 V
Battery 12V Load
48 V
M/G
Battery
Active Chassis
B
Engine
S Motor
G Engine Cooling
Inverter
DC / DC
EPS Heated Windscreen
48V
12V Battery
Battery PTC Heater
E - Turbo Charger
4
1.1 CO2-limits: the discussion and results “Transport accounts for approximately 26 per
In many countries around the world, attempts cent and thus for a significant portion of total
are being made to regulate the CO2 emissions CO2 emissions in the EU. Car traffic, with a total
of road transport (figure 2). While the current share of approximately 12 per cent, is responsi-
absolute limits set for cars vary from region to ble for almost half of these emissions.”1 From
region, all locales demand substantial reduc- 2021 on, all newly registered passenger cars
tions over the coming years. in Germany will be subject to a limit value of
95 g CO2 per km. That corresponds to an aver-
age fuel consumption rate of about 58.8 mpg
(gasoline engines) or 65.3 (diesel). Further
reductions in the years after 2021 are under
discussion. From 2050 on, new cars should not
emit any CO2 at all. The European regulations
take account of the weight of vehicles. The limit
value of 95 g CO2/km applies only to vehicles
with a “standard weight” of 1,350 kg. Heavier
vehicles may emit somewhat higher levels of
CO2, while lighter vehicles must emit less.
Figure 2: International CO2 targets – source: The International Council for Clean Transportation
5
The automotive industry has to make consid- Initially, several arguments seemed to come
erable efforts to meet both the limit values down in favour of the new system: power con-
currently defined and those that will apply sumption and demand were continuing to
in the future. All stakeholders are aware that rise, a need for higher-powered generators to
actions focusing solely on enhancing the effi- meet this increase in demand was perceived,
ciency of the IC engine will not be sufficient. and in the rationale of the time, higher volt-
Additional measures are necessary to reach the ages offered the only chance of achieving this.
target. These include improved aerodynam- Power requirements of well over one kW – for
ics, lightweight design, low rolling resistance solenoid valve control, for example – could not
tires, LED lighting, more efficient transmis- be realised by 12-volt systems, even when only
sions (automatic dual-clutch transmissions) needed very briefly. Finally, the need to intro-
and the electrification of auxiliary components. duce start-stop systems driven by environmen-
Water pumps and air-conditioning compressors tal regulations geared to reducing emissions
can, for example, be driven electrically and at was also a factor, as were the weight decreases
speeds dictated by current requirements rather achievable through the smaller cross-sectional
than directly from IC engines. area of cables in 42-volt systems.
The introduction of a 48-volt starter generator In the further course of the 90s, this solution
to make a “boost and coast” function possible was not phased in on a widespread basis, apart
and allow considerably enhanced recuperation from two car models in Japan and the US, as the
vis-à-vis 12-volt systems is particularly attrac- increased costs associated with the new system
tive. were not matched by functional benefits. In the
interim, generator sizes of 3 kW and higher had
1.2 A look back at the debate on 42-volt come to the market for 12-volt systems, while
systems in 2000 systems with extremely high energy demand
At the beginning of the 90s, as the advanced were not realised. Solenoid valve control, for
development departments of major vehicle example, was not introduced. Start-stop sys-
manufacturers were evaluating the advantages tems integrated into 12-volt systems gained
of higher-voltage systems, the international ground. It seemed that higher voltages were no
42-volt consortium was founded providing a longer going to be needed.
forum for discussions between automobile man-
ufacturers and suppliers. At the time, a 42-volt The 48-volt debate which took off in 2011 may
system was being debated as a replacement for seem superficially similar to this earlier discus-
conventional 12-volt systems. What was termed sion, but the approach now being pursued sets
a 42-volt system was effectively a 36-volt sys- different priorities. 48-volt on-board power sys-
tem with a 36-volt battery - and therefore three tems (48 volts = four times the nominal voltage
times the voltage of conventional 12-volt sys- of 12-volt systems) are being championed as
tems. This voltage (36/42 volts) was chosen with a supplement to 12-volt systems and not as a
the aim of ensuring that voltage in on-board replacement for them. The contact protection
power systems would never exceed 60 volts limit of 60 volts is, however, also of critical
after all tolerances had been factored in, since importance today.
this would avert the need for costly contact
protection. The new on-board power system
was, however, named for the charging voltage
rather than the battery voltage in order to lend
emphasis to the innovative nature of the new
solution.
6
The chief motivation for introducing an addi- At this point, most European automotive man-
tional vehicle electrical system voltage at ufacturers have already decided to introduce
this point in time can be identified in the 48-volt technology to reduce the consumption
above-mentioned EU regulations specifying of their fleets and meet the new European CO2
an average limit value of 95 g CO2/km for pas- limits applicable from 2021 on (figure 3).
senger cars from 2021 on. The threat of finan-
cial penalties for exceeding these new limit
values justifies the deployment of relatively
costly measures. 48-volt systems make it pos-
sible to build on start-stop systems to develop
mild hybrids with remarkable recuperation and
“boost and coast” features. This leads to a drop
in energy consumption and emissions that can
stretch into two-digit percentages.
Figure 3: Scalable platform concept for introducing 48-volt electrical systems – source: Audi
1.3 The market for hybrids – hybrids has emerged. In China, however,
issues and trends all-electric vehicles are particularly in demand.
While the cost-benefit calculations of the major- 48-volt systems still have their development
ity of car buyers still do not seem to be tipping nucleus in Europe, although their advantages
in favour of hybrids, the question remains, as have now been recognised by many automotive
to how the electrification of the powertrain as manufacturers and global programs have been
a mass-market technology could contribute to started accordingly.
reducing CO2 emissions.
With an eye to avoiding high investment costs,
In the foreseeable future, start-stop systems, minimising complexity and facilitating easier
48-volt systems and high-voltage electrifica- maintenance, emphasis is largely being placed
tion will all exist alongside one another in most on finding simple solutions that are easy to
fleets. A strong global trend towards plug-in integrate. This applies, in particular, to the
7
high-volume market for compact and mid-size This allows the implementation of many func-
cars (figure 4), which is subject to strong cost tions familiar from hybrid systems with signif-
pressures. In the most basic case, the alternator icantly higher voltages. Where high-voltage
is replaced with a belt-driven starter generator hybrids allow CO2 emissions reductions of about
(BSG) that operates more efficiently at 48 volts 20-25 per cent (CO2/km), initial results suggest
and starts the IC engine extremely rapidly and that 48-volt mild hybrids can achieve reductions
with minimal noise and vibration. Electric assist of 10-15 per cent in per-km CO2 emissions. A
boosts the responsiveness of the IC engine by comparison of the extra costs shows that the
supplying extra power in specific driving situa- 48-volt mild hybrids are only 30-50 per cent as
tions. This allows additional torque to be mobi- cost-intensive as high-voltage hybrids. As such,
lised. In general, the 12-volt starter battery is the 48-volt system represents an intelligent
supplemented with a 48-volt battery that is and, in particular an affordable supplement to
charged via the BSG in recuperation mode dur- full and plug-in hybrids. Furthermore 48-volt
ing deceleration phases. systems can more easily be integrated into
existing vehicle powertrains and architectures –
fewer extensive modifications are required. As
such, it can be expected that the 48-volt volt-
age level will rapidly become established in the
market.
Figure 4: Mid-sized and compact cars are the volume drivers – source: Continental
8
In addition to the benefits of hybridisation, the Market forecasts predict that 25 per cent of
additional 48-volt system also makes it pos- newly registered cars will have an electrified
sible to operate a selection of electrical com- powertrain by 2025 (figure 5) and that almost
ponents in the vehicle at higher voltages. This half of these will feature 48-volt technology.
is significant because the number of electrical From the year 2020 onwards, global potential
components is continuing to expand dramati- for up to four million 48-volt systems could
cally, especially in the mid-size and luxury car unfold.
markets. High-power components run more
efficiently at higher voltages, and transferring
them to the 48-volt on-board power system also
reduces the load on the 12-volt system.
30.000
Production Volume [k-units]
25.000
20.000 EV
PHEV
15.000 M/FHEV
48V
10.000
5.000
0
2012 2013 2014 2015 2016 2017 2018 2019 2020 2021 2022 2023 2024 2025
1.4 Economic context Given the high cost of R&D and manufactur-
In addition to a long list of technical chal- ing, the quantities of 48-volt components sold
lenges, moves to introduce 48-volt on-board will be of decisive importance. Only if the
power systems have also been flanked by inten- widespread introduction of 48-volt systems is
sive discussions on their economic feasibility. successful will the necessary scale effects be
As the previous sub-chapters have shown, the realised. While the development of 48-volt bat-
main drivers behind the trend towards 48-volt teries can piggy-back on to the established pro-
systems are the continuously increasing power duction of the traction batteries powering bat-
requirements of auxiliary components and, in tery electric vehicles (BEV), the development of
particular, the need to continue to reduce CO2 auxiliary components may well proceed in the
emissions. other direction: 48-volt systems could become
the major force driving developments here.
At the beginning of the last decade, the addi-
tional costs of 42-volt electrical systems (com- Today’s BEVs use specially developed high-volt-
pared to the costs of more powerful 12-volt age components such as air-conditioning com-
systems) were estimated at approximately 600– pressors and electrical heaters. Developing
1,000 euros. It is reasonable to assume that the and manufacturing these components is highly
additional costs for 48-volt systems will be sim- cost-intensive due to the complex safety meas-
ilar now, depending on the respective degree of ures required as a consequence of the high volt-
implementation (starter generator, power elec- ages in use. These components can, as a rule,
tronics, battery, power distribution). If the need only cover a limited range within the high-volt-
to introduce a 48-volt system (to reduce CO2) age spectrum, for example 250 to 450 volts.
is accepted as a given, then it would seem that As the development of high-voltage electrical
these extra costs are ultimately unavoidable. systems continues to progress, voltages of 800 9
volts and higher will probably be introduced in It will not, however, come about overnight. Fun-
the near future. Many high-voltage auxiliary damental questions relating to architectures
components would need to be so heavily mod- remain to be clarified. The systemic approach
ified for these higher voltages that designers has not yet been fully thought through and will
would essentially be starting from scratch, driv- continue to develop and evolve over the com-
ing unit costs to even higher levels. ing years. What it is clear enough, however, is
that the 48-volt system will only enjoy a lasting
While the prospect of on-board power systems future if it is proves possible to standardise key
with three different voltage levels might seem components and to rapidly raise the number of
economically infeasible at first sight, it could units produced to significant levels.
yet prove to be an opportune solution precisely
for economic reasons: 48-volt auxiliary com- 1.5 VDA Recommendation 320
ponents are significantly less costly than their The VDA Recommendation 320 covers electric
high-voltage equivalents. Power outputs of up and electronic components in motor vehicles
to five kW, and more in some cases, can be con- for the development of a 48-volt power supply.
trolled effectively with existing technology. Such It was elaborated in the VDA’s Working Group
components are typically produced in a fashion “Electronics”, project group “48-Volt Power
closer to the 12-volt or 24-volt versions than to Supply”.
high-voltage versions. That is also true for the
costs associated with them. If high-voltage sys- The document defines requirements, test condi-
tems start to utilise very different voltage levels tions and tests performed on electric, electronic
in the medium term, sourcing BEV components and mechatronic components and systems for
from the 48-volt platform concept will become use in motor vehicles with a 48-volt on-board
an increasingly interesting proposition. Both power supply. Unless otherwise indicated, the
all-electric vehicles and 48-volt hybrids would tests described in it are not electric service life
stand to profit from such a development. tests.
36 V - U 48min,unlimited
Lower Limited Operation Range
Limited Operation
24 V - U 48min,low,limited
Undervoltage
20 V - U 48stopprotect
Storage Protection
10
The range between U48r and U48r,dyn represents Requirements for components with 48
the tolerance. connection
• A single error must not cause a short circuit
Upper limited operation range between the 48 volt supply and the 12/24-
The range between U48max,unlimited and U48max- volt supply.
,high,limited
is intended for calibrating the storage • Components simultaneously supplied at 48
medium and for the uptake of recovered volt and 12/24 volt, and interfaces based on
energy. 12/24 volt, need their own ground connec-
tions for both supply voltages. These ground
Unlimited operation range connections must be physically separated
The range between U48min,unlimited and U48max,unlim- from one another.
ited
allows the components to operate without • If a 48-volt component loses its ground (ter-
restriction. minal 31 and/or terminal 41), this must not
disrupt or destroy communication networks
Upper limited operation range or the electrical networks.
The system may operate only temporarily in • Overcurrent tests should be detailed in the
the range from U48min,low,limited to U48min,unlimited. component specifications.
Countermeasures should be taken to bring • No component may cause the voltage to
about a return to the unlimited operation enter the dynamic overvoltage range (e. g.
voltage range. through a load dump or resonance peaks).
• If the voltage enters the overvoltage range
Undervoltage up to U48r, countermeasures should be taken
All voltages below U48min,low,limited are defined as via the component that is feeding energy
undervoltages. The storage protection voltage back in/causing entry into the overvoltage
is U48stoprotect. range, so that the voltage exits the overvolt-
age range at the lower boundary.
Storage protection voltage • If the voltage enters the lower limited
All voltages below U48stoprotect. function range, countermeasures should
be taken so that the voltage returns to the
General requirements unlimited operation range.
Assumptions regarding components with
48-volt connection 1.6 Additional technical challenges
• Static direct voltages ≤ 60 volt occur with a • Safety measures
maximum ripple of 10 percent RMS. From a technical point of view, the 48-volt
• A single error in the wiring harness must not voltage level meets key criteria defined in the
cause the 48-volt supply to short circuit to course of the discussion on 42-volt standard-
the 12/24-volt system. isation around the turn of the millennium. As
• There is a common ground for the 12/24- was already, and wisely, concluded back then,
volt system and the 48-volt system, which staying under the maximum permissible con-
are connected via physically separate tact voltage (< 60 volt) averts the need for
grounding bolts/connections. extensive personal safety measures such as
• All the voltage and current information contact protection, equipotential equalisa-
refers to the component (terminal voltage). tion and insulation control. The “hot plug-
• The polarity of the 48-volt supply is ging” effect must, nevertheless, be given due
prevented from reversing by appropriate consideration even at 48 volt, since opening
measures in the vehicle. an electric circuit under load can be enough
• Jump starting with the 48-volt power supply to destroy plug-in contacts. Safety measures
is prevented by appropriate measures here can either make it impossible to inter-
applied in the vehicle. rupt circuits under load, or ensure that their
disconnection is detected early enough for
the circuits to be deenergised in good time.
11
EMC is also, given the high switched currents, As the number of 48-volt loads is still man-
a significant factor that deserves consid- ageable, load circuits are connected directly
eration. For these reasons, 48-volt electric to the power electronics and monitored there.
circuits are occasionally implemented with As the number of 48-volt high-power loads
shielded cables. In comparison to high-volt- rises, it will become necessary to use electric
age systems, the 48-volt voltage level does power distributors to monitor current paths
not present any risk of personal injury. Costly electronically (in addition to the deployment
personal safety measures are therefore not of safety fuses) so that even creeping short
required. circuits can be detected and switched off in
the event of a fault. Over and above this, it
• 48-volt electricity and power distribution must be ensured that the separation of both
In addition to the obvious difference in volt- the 48-volt and 12-volt systems is main-
age levels, several further technically signif- tained. A 48/12-volt short circuit would cause
icant differences between the 48-volt supply considerable damage to all 12-volt control
voltage and the 12-volt voltage level can be units and loads.
noted.
While breaking an electric circuit under load VDA recommendation 320 specifies that the
in a 12-volt system causes very little arcing, respective power distribution systems should
breaking loaded circuits at 48 volt can trigger be spatially separated. Each should have its
electric arcing that could lead to extensive own routing, and the wiring harnesses should
thermal damage at contact points. Creeping have separate grounding points. All 48-volt
short circuits, in particular, inevitably release components should be clearly distinguisha-
considerable amounts of electric arc energy ble by their colour from other components to
and cannot be de-energised using conven- ensure they are recognised as such.
tional safety fuses.
As such, safety fuses used today are by them- • Electric arcs1
selves not adequate to ensure that all sources As already mentioned, the introduction of
of faults in 48-volt systems are detected and voltage levels higher than 12 volts is accom-
safely switched off. It follows from this that panied by a risk of electric arcs forming if
electric circuits must, in addition to safety loaded circuits in the on-board power sys-
fuses, also be equipped with electronic sens- tem are interrupted. This could happen as a
ing to detect creeping short circuits and the result of the intentional isolation of electrical
formation of electric arcs and switch off the contacts in relays, but it could equally be the
relevant circuits in the event of a fault. result of a fault in a wire or connector..
12
This (figure 7) is what takes place when arc- • A metal vapour arc/anode arc/cath-
ing occurs: ode arc then forms (the temperature
• As the two contact surfaces separate required for an arc to ignite depends on
from each other when a connector is the specific materials, but if the burning
unmated, the reduced contact force voltage of the material is reached, an
before they open at the breaking point arc will ignite).
leads to increased contact resistance in • A gas/plasma arc forms.
the contact zone. • If measures are not then taken to extin-
• Formation of a bridge of molten metal guish the arc – by further increasing the
(the contact points begin to open: the distance between the contacts or using
increase in the strength of the electric arc chambers with magnets – very high
field causes material to begin to melt.) temperatures in the arc could lead to
• As the gap between the contacts gets thermal damage in its surroundings.
larger, the temperature of the bridge
rises until the melting voltage of the
contact material is reached.
Using relays to switch loads under 12 volt and • Load limit curve
24 volt is a known and safe practice in passen- The switching capacity of a relay is normally
ger and commercial vehicles. In 48-volt appli- estimated using what is generally termed the
cations, new challenges present themselves. In load limit curve 2. This gives the load current
principle, steadily burning DC arcs can form – load voltage pairs in which safe shutdown
when switching conventional 12-volt relays. can be realised for Ohmic loads.
This mainly depends on the contact spacing. If
the distance between contacts is too small, the Figure 8 shows the load limit curve of a
electric circuit might not be interrupted when switching relay K (with single contacts) and
the contacts open, and the continuously burn- of a switching relay K-B (bridge contact) for
ing arc could destroy the relay. resistive loads. Values below the respective
load limit curve indicate that arcs are sure
to extinguish within, at most, ten ms. Values
13
above the load limit curve indicate that a sta- If a single interruption with a given contact
ble arc forms – one which does not extinguish spacing does not suffice to switch off a cir-
even when the contacts are fully open. cuit, various options for the design of the
switching contacts are available to increase
the arc voltage:
14
2. Architectures
Engine MT
48V e-Drive
48V e-Drive
Engine
Automated
Transmission
Figure 10: Crankshaft-mounted 48-volt electrical machine – source: Robert Bosch
15
The introduction dates and prioritisation of the The easiest mode of integrating the electrical
individual topologies differ between the vari- machine and the most extensively analysed
ous manufacturers, and depend on the efforts topology to date is illustrated in figure 9.
required to achieve defined CO2 target values,
on regional requirements and on the scope of
features offered to the end customer.
Engine
Double Clutch
Transmission
Figure 11: Dual-clutch transmission-mounted 48-volt electrical machine – source: Robert Bosch
MT/AMT
48V e-Drive
Figure 12: 48-volt electrical machine mounted to the transmission output shaft – source: Robert Bosch
16
2.2 Types of electrical system topologies
The maximum and continuous current deter-
mine the configuration of the electrical system.
12-volt electrical systems will be equipped with
lead-acid batteries for the foreseeable future
due to their ability to start the engine even at
very low temperatures. In addition, this low-cost
solution has been tried and tested for many
decades.
Figure 14: 12-volt full load – source: Leopold Kostal
The current limit is to be set to 250 A contin-
uous current for both systems. However, short
peak currents may be significantly higher. • 12-volt systems with higher voltage loads
Higher continuous currents require larger cable Higher voltages are already used in vehicles
cross-sections, which adds bulk and drives up to supply headlights and windshield defrost-
costs. Since the 48-volt system primarily sup- ers. These power-consuming devices produce
plies high-power components, it is currently the required voltage themselves locally (fig-
switched off in most applications when the ure 15).
vehicle is not moving.
17
Capacitors can also be used to store electric when the IC engine is running. The DC/DC
power in addition to batteries. The 12-volt converter transfers part of this energy to the
lead-acid battery still supplies the power to 12-volt system to supply its components and
start the engine (figure 16). charge the lead battery (figure 17).
Bild 17: Start of an IC engine with 12-volt starter, when the lithium-ion battery is too cold – source: Leopold Kostal
Figure 18: Start of an IC engine with 48-volt starter and transfer of power from 12-volt system via DC/DC converter, when the lithium-ion
battery is too cold – source: Leopold Kostal
18
3. Components
Salient- Claw-pole Rotor with rare Rotor with Copper rotor Aluminium rotor
pole rotor rotor earth magnets ferrite magnets
19
As a result of the multiple topologies and
machine types available, no single “stand-
ard architecture” or “standard machine type”
will dominate. In fact, the introduction of the
48-volt system will lead to variabilisation as a
result of different factors such as the required
torque, existing platforms, costs, package
space, robustness and CO2 targets.
Figure 20: Belt-driven e-machine – source: Valeo
20
Having already become accepted in 12-volt The air-conditioning system uses the air-to-wa-
systems, this heater technology will most ter heat exchanger of the cooling circuit to heat
likely be the first to be used in 48-volt sys- the vehicle interior and defrost the windshield.
tems due to its easy transferability. Other Compared to an air heater, the heat transfer
heating technologies (wire heaters, layer loss is higher since the heat is transferred twice.
heaters) are also conceivable. Which tech- However, by heating the coolant, the IC engine
nology will prevail still remains to be seen, can be brought quickly to its operating temper-
since it will depend on multiple factors such ature and the temperature of the 48-volt bat-
as costs and the electrical behaviour of the tery can be controlled with the heating system.
heaters in the on-board power system. If nec-
essary, an additional heater will be used to
heat the lithium-ion battery.
• Water heaters
The water heater is tied into the hydraulics of
the engine coolant system (figure 22).
21
Figure 23: Electric compressor – source: Mahle Behr Figure 24: Electric coolant pump – source: Brose
The use of 48-volt compressors is technically Transmission fluid and engine oil pumps (fig-
feasible but requires substantial changes to ure 25) can fully replace today’s mechanical
the electric system. Space requirements, weight main pumps and electric auxiliary oil pumps,
and costs all increase as a result. The defined while optimising the costs and efficiency of
package space must be adjusted to the dimen- automatic transmissions and maintaining
sions of 48-volt compressors. the oil pressure after the IC engine has been
switched off.
3.4 Pumps
The 48-volt system promotes the use of power-
ful electrically-operated auxiliary components.
These include various pumps (for oil, coolant,
air, fuels). They can be activated on demand
and controlled, thus reducing energy consump-
tion and emissions while also minimising wear
and tear. The maximum output increases from
currently around one kW to six kW. A clear
market trend towards higher power outputs in
combination with better control and analysis
options can currently be identified.
Electric coolant pumps contribute to the imple- Figure 25: Electric oil pump – source: Brose
22
As a result of increasingly larger glass surfaces In modern vehicles, window heaters primarily
and higher requirements for the melting speed, perform a comfort function when the engine is
power peaks of more than one kW occur in started. It usually takes only a few minutes to
these systems. Power densities of 1,000 W/m2 thaw frost from the windows. The heating is also
are usually necessary to achieve subjectively used to prevent or clear condensation.
quick defrosting (figure 26).
It is therefore safe to assume that window heat- Direct electric heating of the window is more
ers will become more important, especially in efficient and can be controlled better than
future electric vehicles without IC engines where indirect heating with hot air. In this context,
they are likely to be deployed more often. Care- extension of electric heating to other car win-
ful energy consumption is essential in these dows also appears desirable. Complete heat-
vehicles since the use of HVAC can sometimes ing of all windows would require a connected
reduce the driving range of an electric car quite load of up to 2.5 kW for a total surface area of
significantly. 2-3 m2. 48-volt systems can help provide the
high power required for window heating, which
However, lower energy usage for cabin heating may sometimes be drawn for extended periods
and air-conditioning will considerably increase of time, as an integral component of the car’s
the risk of fogging and condensation on all air-conditioning system.
windows. In addition to defrosting the windows
when starting the car, window heaters will most
likely also be used in continuous operation to
prevent fogging and condensation while the
vehicle is moving.
23
3.6 Chassis functions In this respect, EPS does not require a 48-volt
The power consumption of electrically pow- supply. The question as to whether the ben-
ered chassis systems with peaks in the kilowatt efits of EPS using a 48-volt motor may jus-
range is high for the on-board power systems tify conversion still needs clarification. Con-
of passenger cars. Examples are electric power sequently, EPS is not a driving force behind
steering (EPS), rear steering, roll stabilisation the introduction of 48-volt electrical systems.
and active suspension/damping. As a result of However, it is rather likely that the possibility
the power requirements, chassis systems are of 48-volt EPS will be investigated as soon
automatically candidates for a 48-volt supply, as such 48-volt systems have been realised.
which is even already demanded by some chas- The 48-volt solution can offer particular ben-
sis systems. efits for vehicles equipped with EPS and rear
steering. The steering systems on the front
Electric power steering and roll stabilisation are and rear axle are controlled simultaneously
described in more detail below. and thus require higher peak power from the
electrical system. The use of a 48-volt system
• Electric power steering (EPS) could significantly reduce the loads, which
Until the end of the nineties, the notion pre- the 12-volt system has to supply.
vailed that EPS could only handle front axle
loads in small to mid-size cars. The energy • Roll stabilisation
provided by the 12-volt motor was insuf- In 2014, a major carmaker presented an
ficient to ensure adequate power steering electric roll stabilisation system running on
support. Executive and luxury cars were fitted 48 volts (figure 27).
with hydraulic power steering. Technologi-
cal developments in electric power steering The concept features a standard 12-volt
enabled increasingly higher axle loads. EPS on-board power system and a DC/DC con-
running on 12 volts can nowadays be used verter that generates 48 V for the exclusive
in almost all passenger cars and is likely to supply of the electric roll stabilisation system.
replace hydraulic power steering. Consequently, it is not a 48-volt on-board
power system but rather a 48-volt stand-
alone solution. This stand-alone solution
can be considered as the first step towards
48-volt electrical systems.
• Package space
In terms of package space, 48-volt systems
provide no benefits for chassis actuators.
While 12-volt actuators have a lower num- Figure 28: Cooling fan drive for low performance classes (up to
600 W output power) – source: Brose
ber of turns than 48-volt actuators, their
wire cross-section is higher. If winding space
and power requirements remain unchanged,
48-volt actuators will provide no significant
package space benefits compared to 12-volt
systems.
26
With regard to the system architecture, cost sav-
ings result from the following reduced require-
ments:
• no contact protection required in connectors
• no special dielectric strength (creepage
distance and clearance) required
• no shielded cables required
• no HVIL pilot line (to prevent disconnection
under load) required
• no isolated grounding (B-) requiredh
27
The need to avoid particular short circuit sce- One of the main differences lies in the power
narios will require complex and expensive semiconductors used. Unlike the high-voltage
fusing and cable routing solutions resembling systems using primarily IGBTs (Insulated Gate
those used in high-voltage systems. A system Bipolar Transistors), MOSFETs are predestined
with e. g. 15 kW power potential could be for use as switching elements in inverters for
designed as a high-voltage system with con- starter generators due to their lower voltages.
siderably smaller connectors and cables than a To control a 3-i-phase machine, MOSFETs are
comparable 48-volt system. Today’s high-volt- configured as three half-bridges.
age systems are not optimised for this power
class. When systems with a similar level of 3.11 DC/DC converters
functionality are compared, the high-voltage A voltage converter (DC/DC converter) is used to
systems emerge as the winners in some areas. transfer energy between the two subsystems of
a dual voltage system. Since it mostly transfers
3.10 Inverters energy from the 48-volt system to the 12-volt
A bidirectional inverter is required for operating level, it is primarily operated as a step-down
a starter generator. This inverter transforms the converter. In this energy transfer direction, the
battery’s direct current into a 3-phase alternat- DC/DC converter replaces the generator for the
ing current, supplying the individual windings traditional 12-volt system. Scenarios with con-
of the electrical machine with electric energy. verters operating in step-up mode usually only
The energy flow is reversed for recuperation. In involve partial load requirements to ensure
this case, the inverter transforms the alternating 48-volt operation. Alternatively, they can be
current generated into direct current to charge stand-alone system solutions without a 48-volt
the battery. In terms of its functional configu- generator.
ration, the inverter of 48-volt systems is similar
to that of the high-voltage inverters used in full The evaluation of various application scenarios
hybrids or all-electric cars (figure 32). of 48-volt implementation with and without
48-volt components reveals that the voltage
converter needs to be implemented in different
power classes from one to three kW. To ensure
cost-efficient production, a modular and scala-
12V 48V
ble converter architecture is necessary to sup-
Control + Driver Board IMS port the different power classes. The scalable
converter must be configured with multi-phase
2nd Safety Path
48V
12V Gnd Gnd Motor
Position
P&T Motor
Receive Temperature
28
Figure 33: Block diagram of scalable 48 volt/12 volt DC/DC converter in half-bridge topology
29
The battery always consists of the following To control the operating range of the battery, it
component groups: is necessary to measure the current, individual
• cell pack (energy storage) cell voltages and the temperature at selected
• battery management system (monitoring, points. The battery system typically uses a
measuring and controlling) communication interface to communicate with
• thermal management the electrical system. Battery current and volt-
• housing, peripheral devices and interfaces age are controlled based on the battery status
(mechanical protection, fixing, vehicle (charging status, maximum charging and dis-
connection) charging rate, current limits). Lithium-ion bat-
teries are typically operated at a temperature
The cell pack consists of a number of cells range between -30°C and +60°C, but full dis-
determined by the cell chemistry selected and charge performance is only achieved within a
connected together in series. Depending on range from approx. 0°C to 35°C. Refrigerants,
the required battery capacity and the individ- cooling liquids or air can be used to keep the
ual capacity of the selected cells, several cells battery temperature within a defined temper-
or battery strings can be connected in paral- ature range. Passive temperature control can
lel. Although prismatic cells or pouch cells are also be sufficient in certain cases..
preferably used, round cells are also available.
Voltage levels and limits under different oper- The dimensions of current lead starter batter-
ating conditions are defined in standards such ies can be used as a guide when developing
as VDA 320. 48-volt batteries. However, they may vary sub-
ject to the installation space and environment
The voltage level and cell capacity are deter- or mounting concept. A range of safety stand-
mined by the anode and cathode types used. ards that are specific to the automotive indus-
Most commercial cells currently employ a try have been developed for lithium-ion cells
graphite, hard carbon or lithium titanate (LTO) and batteries in recent years and must also be
based anode. The cathode is usually made up of considered in the development of 48-volt lithi-
lithium nickel manganese cobalt oxide (NMC) um-ion batteries.
or lithium iron phosphate (LFP). The materials
used for the anode and cathode affect the bat- 3.13 Active electronic components
tery’s performance in addition to the voltage The electronic control units of 48-volt systems
level. always follow the same fundamental structure
as those used in 12-volt or high-voltage sys-
The battery management unit (BMU/BMS) ena- tems. However, the semiconductor elements
bles the following functions: selected for 48-volt applications must take the
• maintenance of an optimal operating range different voltage level and different loads into
to ensure the battery can meet the require- account. They are mainly used in 48-volt sys-
ments of the application and to prolong bat- tems to control electric motors and other elec-
tery life, tric loads in addition to connecting the 48-volt
• ensuring safe and reliable operation, and 12-volt system levels by means of a DC/
• communication with the control and man- DC converter. The necessary semiconductor ele-
agement system of the host application ments can be classified as sensors, microcon-
(vehicle). trollers and power ICs, supply, communication
and driver ICs.
30
Figure 36: Semiconductor elements for start/stop and generator control in a 48-volt system – source: Infineon Technologies
The block diagram (figure 36) depicts the basic using several communication buses. The sensor
structure of semiconductors for the control of signals are processed to determine the current
the starter generator in a 48-volt system. It motor and inverter status. The microcontroller
includes an extra output stage to control the uses appropriate circuitry components to sup-
exciting current during generator operation in port the implementation of security features to
addition to the output stages required for the guard against manipulation (hardware security
motor control. For the voltage supply of the module, HSM).
microcontroller, the system voltage (48 volts) is
reduced to a level commonly used for microcon- MOSFETs are often used in 48-volt systems as
trollers and other ICs. This is the main task of power output stage ICs. Compared to IGBTs,
the supply IC. It also performs additional tasks their performance regarding switching and con-
relating to functional safety. The microcon- duction losses is significantly better in the volt-
troller is the “brain” of the control system and age range of 48-volt systems. In addition to the
ensures the field-oriented control of the electric actual configuration of semiconductor switches
motor as well as the control of the exciter wind- for currents of more than 100 amperes, it is
ing during generator operation. Complex timer also very important to ensure sufficiently good
units have been implemented for this in the dissipation of lost heat (cooling) by choosing
microcontroller. The microcontroller also com- appropriate power semiconductor case styles.
municates with other control units in the vehicle Different case styles are possible subject to the
31
configuration of the control unit, ranging from The sensors are used to detect the rotor’s posi-
standard-TO-cases for single transistors and the tion in the electric motor and the actual cur-
integration of output stages (one or all stages) rents flowing in the inverter, and to transmit
into one power module to the direct integration this information to the microcontroller. The
of power components into the motor. rotor position can be detected using encoders
or magnetic field sensors (figure 37). In the lat-
Driver ICs are another important element. Their ter case, a magnet is attached to the rotor hub.
primary purpose is to adjust the (PWM) signals A suitable magnetic field sensor stationed near
generated by the microcontroller to control the the rotor then detects the angular position and
motor to the level required for the power output speed of the rotor. Intelligent sensor ICs can
stages. It may sometimes be necessary to use already process the measured data internally
several drivers to ensure this is achieved. within the ICs and transmit this data as digital
values to the microcontroller via a sensor bus.
Figure 37: Rotor detection with highly-integrated magnetic field sensors (schematic illustration)
– source: Infineon Technologies
32
Multiple options are possible for the design These result in different circuit topologies
of a DC/DC converter depending on individual (single-phase, two-phase or multi-phase). The
requirements. The most important require- choice of converter frequency is also important.
ments are: Semiconductor components such as microcon-
• converter performance, trollers, driver ICs and power output stages,
• power loss (efficiency), supply and communication ICs are also used
• package space/volume (W/l), here to perform this function. The selection
• uni or bidirectional power transfer, of the types depends on the definition of the
• galvanic coupling or separation, parameters mentioned above. This applies par-
• functional safety classification. ticularly to the selection of power ICs and driver
ICs.
33
The most important task of power induc-
tors (figure 41) is the short-term storage of
energy in the form of magnetic energy. As
storage chokes, they are key components in
buck and boost converters in 48-volt electri-
cal systems. High-power inductors can, for
example, be deployed as storage chokes in
DC/DC converters. Flat wire winding ensures
a high copper fill factor which in turn reduces
losses.
Figure 39: Multi-pin film capacitor for use in DC links –
source: Epcos
Figure 40: Ceramic capacitors are suited for use as IGBT snubbers,
or as DC link capacitors in DC/DC converters –
source: TDK Corporation
34
Figure 42: Power inductors as storage chokes for relatively small
DC/DC converters or for smoothing currents in other assemblies –
source: Epcos
Figure 43: Common-mode chokes (CMC) –
source: Vacuumschmelze
• Filter chokes and common-mode chokes
for EMC filtering • Magnets
In addition to storage chokes for storing elec- It is important that the overall efficiency of
tric energy, filter chokes and common-mode hybrid vehicles be as high as possible. As a
chokes (figure 43) are used for EMC filter- result, generators and electric motors not
ing. Solutions using nanocrystalline cores only need to be as efficient as possible, but
have proven effective for the common-mode they must also be built in a way that saves
chokes. Single core solutions are a good weight. The magnets used (figure 44) play a
choice here because of the high currents decisive role in achieving this. New neodym-
and the resulting necessity for copper con- ium magnets offer more than 10 times the
ductors used together with ring cores made energy density of ferrite permanent magnets.
from nanocrystalline ribbon wire. The high These excellent values are achieved through
permeability of the nanocrystalline magnetic lower oxide contamination of the magnetic
material ensures excellent smoothing over material and a significantly finer microstruc-
a broad range of frequencies with minimal ture.
temperature dependence.
35
4. Summary and Outlook
The introduction of an additional voltage level The technical implementation of the 48-volt
in vehicles offers many advantages in compar- voltage level into the powertrain is more
ison to high-voltage hybrid vehicles. It facili- straightforward than the realisation of
tates the realisation of attractive reductions high-voltage hybrid designs, since existing
in CO2 emissions at acceptable cost levels, powertrain concepts can largely be retained. As
and it allows features to be realised that are such, it can be assumed that developments in
technically difficult to implement in today’s this area will progress rapidly to series produc-
12-volt environment. These include electric tion. Implementation will demand, of course,
turbo-chargers, air-conditioning compressors that components and systems are developed
and various pumps that operate independently at every level and integrated and validated in
of engine speed. With features like these, it this context. Manufacturers are already working
becomes possible to efficiently switch loads on intensively towards this goal.
and off or to trim them in the context of the
applicable driving situation. The advantage lies
in the optimisation of the dynamic properties
of vehicles – electrically supported acceleration
and environmentally friendly braking.
36
5. List of Abbreviations
A HV
Amperes High Voltage
AC HV-Hybrid
Alternating Current High Voltage hybrid
BDSG IC engine
Belt-Driven Starter Generator Internal Combustion Engine
BEV ISG
Battery Electric Vehicle Integrated Starter Generator
BG kW
Booster Generator Kilowatt
BSG M/G
Belt-driven Starter Generator Motor/Generator
C LIN
Celsius Local Interconnect Network
CMC-Drosseln MCU
Common Mode Choke (stromkompensierte Microcontroller Unit
Drossel)
MOSFET
DC Metal Oxide Semiconductor Field Effect Transis-
Direct Current tor
DIN-EN OEM
German adoption of a European Norm (EN) Original Equipment Manufacturer
EMC PWM
Electromagnetic Compatibility Pulse-Width Modulation
EMI RMS
Electromagnetic Interference Root Mean Square
EPS S
Electric Power Steering Starter
G SOC
Generator State of Charge
HSM SOH
Hardware Security Module State of Health
HVAC V
Heating, Ventilation and Air Conditioning Volt
37
VDA
German Association of the Automotive Industry
VDE
German Association for Electrical, Electronic
and Information Technologies
W
Watt
38
39
ZVEI - German Electrical and Electronic
Manufacturers’ Association
Lyoner Strasse 9
Quelle Titelbild: Continental