HowtoDesign48VoltVehicles

Teslahasbeenexpandingitsvehicleproductionaboutasfastasallofitscompetitorscombined.Teslapresentlyaccountsforover60%offullelectriccarssoldintheUS.

TeslaclaimstheirrecentlylaunchedCybertruckutilizesa48Vlow-voltagearchitecture,andhasindicatedalltheirfuturevehicleswillutilizea48voltsystem.

InearlyDecember2023,ElonMusksentotherOEMCEOsarecipefordesigning48Vvehicles.Althoughthereisnothingnovelaboutitscontents,3IShasreceivedmultiplerequestsforthecopyrighteddocument.TheinformationpresentedhereisafacsimileofMr.Musk’spaper.

48-Voltvehiclearchitecturesisnotanewconcept…

AutomotiveOEMshavelongrealized

?Decreasedcurrentconsumptionincreasedefficiencies(1/4amper

?Smallerwirecross-sections(less

?Smallerwirebundles,connectors

?Componentandsystemweightre

ICs&ECUs

Power

Distribution

Power

Consumption

thebenefitsof48Vsystems:

&powerdissipation,

age,1/16losses)

conductormaterial)

,heatsinks,misc.componentsductions

LowVoltageSystemCategories

PowerSupply

VoltageConversion

LowVoltageArchitectureCategories(1of3)

DCPower

BatteriesandStorage

?Existingtechnologyreadilyutilized

?Industryconsensusforoperationalstandards

VoltageConversion

LowVoltageManagement

?48Vto12V,5V,3.3V(etc.)

?Legacyinfrastructure

?Bi-directionalcapability

LowVoltageArchitectureCategories(2of3)

ICs&ECUs

Semiconductorrequirementsforcomputing&loadmanagement

?Transitionto48Vwherepracticable;prioritizehigh-powerconsumptiondevices

?12V,5V,and3.3Vintegratedcircuitsremain

Power

Distribution

Connectors,harnesses,andhandling

?Smallerconnectors,greaterpin-countdensity

?Eliminatedamagefromarcing

?Harnessminiaturization

?Flexible/intelligentpowermanagementanddistribution

LowVoltageArchitectureCategories(3of3)

owerconsumptionloads:

ngandcontrol(ADAS,BodyControl,

on,A/C)

ESC,BlowerFans,ParkBrake,Liftgate,ering,Seats,WindshieldWipers,etc.)

ActuatorandSensorLoads

?Prioritizetransitionofhigh-p

?High-poweredcomputiInfotainment)

?Compressors(Suspensi

?Motors(BrakeBooster,WindowLift,PowerSte

?Heaters

?Pumps

?ExteriorLighting

Power

Consumption

OtherConsiderations

?Fusingandcircuitprotectionstrategies

(Tesla’sexistingeFuseprotection-allcarlines-is48Vcapable)

?48Varcpreventionandmitigation

?Lowvoltageconversionefficiencies(capacitor-basedvsmagnetics)

?Communicationnetworkingconsiderations

?48Vsupplychaincomplianceands