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Intergration of 48V wire harness in vehicles
Date Created: 2014-05-30 1
IQPC - Advanced Automotive Cabling, Stuttgart June 24 - 26 2014
Integration of 48V wire harness in vehicles– Peter Berggren– Volvo Car Corporation
Peter Berggren Senior Engineer
Project leader for integration of 48V
Volvo Car Corporation
Agenda
• Background
• Tests results
• Requirements
• Conclusions
Intergration of 48V wire harness in vehicles
Date Created: 2014-05-30 2 Integration of 48V wire harness in vehicles– Peter Berggren– Volvo Car Corporation
Background
Why do we need 48V?
It will not replace the 12V system!
48V system will be a complement to the 12V system.
Date Created: 2014-05-30 3 Integration of 48V wire harness in vehicles– Peter Berggren– Volvo Car Corporation
B-ISG
48V 12V DC
DC
Z12 Z48 SM
Why do we need 48V?
• Enabler to reach CO2 requirement in 2020 in Europe.
(<95g/km)
• 12V system is close to it’s maximum capability.
Date Created: 2014-05-30 4 Integration of 48V wire harness in vehicles– Peter Berggren– Volvo Car Corporation
Why 48V? Personal safety limit
Date Created: 2014-05-30 6 Integration of 48V wire harness in vehicles– Peter Berggren– Volvo Car Corporation
Today’s Micro hybrid
12V
3kW
Future Micro hybrid
48V
10kW – 12kW
• Stop/Start • Limited break
recuperation
• Stop/Start in speed
• Brake energy recuperation
• Coasting
Mild hybrid
>60V
>18kW
• Stop/Start in speed
• Brake energy recuperation
• Coasting • Low speed
electric drive
Full hybrid
>120V
>30kW • Stop/Start in
speed • Brake energy
recuperation
• Coasting • Electric drive
g CO2/km emission Cost
Will the wires be thinner with 48V?
Yes. For components moved from 12V.
Example:
A 1000W component (e.g. heated windscreen) with 3 meter long 16mm2 wire
will change to 2,5mm2 wire. The delta weight for copper will be 390g.
For the wire between 48V ISG and battery. Yes and No.
In case of 48V kinetic energy recovery system, KERS.
The thinner we make this wire, the less CO2 we save.
Date Created: 2014-05-30 7 Integration of 48V wire harness in vehicles– Peter Berggren– Volvo Car Corporation
Example
12V
• 100A
• 1,5V
48V
• 25A
• 1,5V
16V
9V
18V
6V
4,5V
12V
Date Created: 2014-05-30 8 Integration of 48V wire harness in vehicles– Peter Berggren– Volvo Car Corporation
Voltage range of 16V Voltage range of 7V
Test EXAMPLES AND RESULTS
Serial
Parallel
Live disconnect
Ring terminal with
poorly tightened nut
Live connect
Wire dropped to plate
edge
12V 48V
Wire chafed against
plate edge
Short circuit, 48V to
12V
Date Created: 2014-05-30 9 Integration of 48V wire harness in vehicles– Peter Berggren– Volvo Car Corporation
48V_40A_wo_
cap_disconne
ct_YESC
48V_40A_with_c
ap_disconnect_Y
ESC
Requirements
LV148
• Within the wiring harness it is
ensured, that a short circuit,
caused by a single malfunction,
cannot occur between the BN48 and
the BN12/BN24.
Routing is very important for 48V!
• There is a common ground
potential for the BN12/BN24
and BN48, which is connected
by spatially divided ground
terminals.
Date Created: 2014-05-30 10 Integration of 48V wire harness in vehicles– Peter Berggren– Volvo Car Corporation
How protect a 48V wire
250A 1000A
Normal Fuse will handle Battery switch will handle
12kW
brake
energy
0A
Date Created: 2014-05-30 11 Integration of 48V wire harness in vehicles– Peter Berggren– Volvo Car Corporation
Conclusions
• 48V is low voltage
No personnel protection
• 48V can not directly be treated as 12V
• Below 40A we are well protected by the fuse.
• Above 40A we need an active protection as well.
Date Created: 2014-05-30 12 Integration of 48V wire harness in vehicles– Peter Berggren– Volvo Car Corporation
• In events of short circuit between12V and 48V, there is a
risk that the 12V system will be damaged!
Conclusions
• Connectors should be designed in such way that it is not possible to disconnect them in a slow way.
• In case of use of ring terminals it is important to have a process that makes sure that they are correct tightened.
Date Created: 2014-05-30 13 Integration of 48V wire harness in vehicles– Peter Berggren– Volvo Car Corporation
Thank you all for listening!
Any questions?
Date Created: 2014-05-30 14 Integration of 48V wire harness in vehicles– Peter Berggren– Volvo Car Corporation