The commercial vehicle industry stands at a pivotal juncture, where strict emissions regulations and increasing power demands are colliding, pushing manufacturers to innovate. One promising solution to this challenge is the adoption of 48-volt electrical systems. This shift from traditional 12- and 24-volt architectures offers several compelling advantages, including improved vehicle performance and reduced emissions.

The pressing need for change

Across the globe, emission standards are tightening for vehicle manufacturers. The California Air Resources Board (CARB) and the U.S. Environmental Protection Agency (EPA) are set to implement stricter regulations in 2027. Meanwhile, in Europe, the introduction of Euro VII standards is anticipated between 2028 and 2029. China is also aligning its future standards to be as stringent as, if not more severe than, the current European benchmarks.

These forthcoming regulations aim to reduce tailpipe NOx emissions by up to 90% and CO2 emissions by up to 30%. Such extreme reductions accelerate the need for global engine manufacturers to employ additional emission reduction strategies, and 48-volt electrical systems are increasingly being adopted.

Why 48-Volt Systems

Traditional 12- and 24-volt systems have served the commercial vehicle industry well, but the evolving landscape now demands more power to support components such as advanced driver assistance systems (ADAS), electrified HVAC systems, and catalyst heating technologies. A 48-volt architecture can efficiently meet these heightened power requirements while facilitating significant reductions in both emissions and fuel consumption.

Enhanced Power Capabilities

The transition to 48-volt systems allows for the electrification of components traditionally driven by the engine, such as air conditioning compressors, cooling fans, and power steering pumps. Electrified versions of these components not only reduce parasitic losses, enhancing fuel efficiency by up to 2%, but also improve packaging flexibility, which can lead to better aerodynamics and further fuel savings.

Mild Hybridization

A 48-volt architecture also paves the way for mild hybrid systems in commercial vehicles. Mild hybrids can capture and reuse energy that would otherwise be lost, providing a boost to the powertrain during acceleration and enabling engine-off coasting. This not only improves fuel economy but also reduces emissions by maintaining optimal engine operation.

Efficient Aftertreatment Systems

A critical challenge to meeting future NOx regulations is maintaining the aftertreatment system within its optimal efficiency range. A 48-volt electrical system can power electrified heaters that quickly heat the aftertreatment catalyst up to the required temperature, ensuring it operates efficiently even during low load conditions. This can result in significant NOx reductions, contributing to compliance with stringent emissions standards.

Developing tailored solutions

As the commercial vehicle industry navigates the twin challenges of meeting tightening emissions standards and satisfying the rising power demands of modern vehicles, 48-volt electrical architectures are standing out as the ideal solution.

Eaton’s expertise in low-, medium- and high-voltage systems enables the development of fully integrated 48-volt electrical systems with power electronics that meet commercial vehicle duty cycles and durability requirements. This expertise ensures that fleet managers can confidently embrace the future of emissions compliance and power efficiency. Learn more at eaton.com.