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Eaton Introduces DC-DC Converters for 48-Volt Commercial Vehicle Architectures

Technology Cover
Post Date: 2022-08-03, Eaton

    Power management company Eaton today introduced a range of 48-volt DC-DC converters for diesel-powered commercial vehicles that can be used to power vehicle accessory systems such as anti-lock braking and lighting. Eaton's DC-DC converters can operate in ambient temperatures up to 85 degrees Celsius and have a design efficiency of 97%.

    Ben Karrer, Director of Technology Development, Eaton’s eMobility business unit, said: “DC-DC converters are an important part of our eMobility product portfolio and can be used in a variety of vehicle applications. Many commercial vehicle manufacturers are transitioning to 48-volt architectures, so they can efficiently Converting the power supply system from high voltage to low voltage becomes critical. We are pleased to offer a power conversion technology specifically designed for the needs of commercial vehicle electrical systems.”

     Eaton's DC-DC converters step down the 48 volt system voltage to 24 volts. The bidirectional unit then further reduces the voltage to 12 volts for use in low voltage systems, while also charging the 12 volt battery in case the mains supply fails. A range of DC-DC converters are available that meet the functional requirements of Automotive Safety Integrity Level (ASIL) B and can be optimized to work seamlessly with manufacturer's alternator specifications. These converters can also be tuned for specific duty cycles through an advanced digital control architecture and support flexible control modes through software adaptation.

     The DC-DC power converter is also equipped with a dedicated High Power Lock Box (HPLB) power connector. HPLB connectors were designed by Royal Power Solutions, a leading manufacturer of high-precision electrical connection components, acquired by Eaton earlier this year. HPLB terminals offer superior efficiency and reliability with component protection. In addition, the HPLB terminal is waterproof to a depth of one meter and is strong enough to withstand the jets of high-pressure water guns.

     Eaton's DC-DC converters have built-in noise reduction and interference suppression technology that will not be affected by or interfere with onboard electronics. In addition, Eaton's air-cooled DC-DC converters are designed for efficiency to reduce power loss over a wide range of operating conditions, and their innovative die-cast design features a fin construction for extreme heat dissipation.

     Karrer said: “Our converters are robust, highly hermetically sealed, resistant to environmental factors such as salt spray and water, and have good vibration resistance. The demands of modern commercial vehicle manufacturers for reliable energy management of high-power loads, This product is the ideal solution.” The 48-volt architecture of commercial vehicles also creates the possibility of mild hybridization of the drive system. Additionally, a higher voltage power supply system can be used to power an electric heater to quickly heat the vehicle's aftertreatment catalyst to help reduce emissions.

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