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

Power management company Eaton today introduced a family of 48-volt DC-DC converters for diesel-powered commercial vehicles that can be used to power accessories such as antilock brakes and lighting. Unlike competitive offerings, Eaton’s DC-DC converters are operational in ambient temperatures up to 85 degrees Celsius and boast 97% design efficiency.

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“DC-DC converters are an essential part of our eMobility product portfolio and are used in a variety of vehicle applications,” said Ben Karrer, director, Technology Development, Eaton’s eMobility business. “Many commercial vehicle manufacturers are transitioning to 48-volt architectures, so having the ability to efficiently convert power from high to low voltage is critical. We’re delighted to deliver power-conversion technology designed specifically to meet the demands of commercial vehicle electrical systems.”

Eaton’s DC-DC converter takes power from a 48-volt system and reduces it to 24 volts. The bi-directional unit then further reduces the power to 12 volts for use in low-voltage systems and charges a 12-volt battery that stores power in case of a fault in the main power supply.

Eaton offers a family of DC-DC converters that adhere to Automotive Safety Integrity Level (ASIL) B functional requirements and can be optimized to work seamlessly with a manufacturer’s alternator specifications. The converters can also be tuned for specific duty cycles via advanced digital control architecture, enabling flexible control modes through firmware adaptation.

The DC-DC power converter also features specialized high-power lock box (HPLB) power connectors. The HPLB connectors are designed by Royal Power Solutions, a leading manufacturer of high-precision electrical connectivity components that Eaton acquired earlier this year.

The DC-DC power converter’s HPLB terminals provide superior efficiency and reliability as well as protection against the elements. Additionally, the HPLB terminals are waterproof up to one meter deep and strong enough to withstand high-pressure water spray.

Eaton’s DC-DC converter includes noise reduction and rejection technologies, so the unit is unaffected by and does not interfere with vehicle electronics. Additionally, unlike competitive technologies, the design efficiency of Eaton’s air-cooled DC-DC converters reduces power loss over a wide operating range, while the innovative die-cast design features a fin pattern that delivers optimal thermal performance.

“The converter is rugged and robust, sealed against environmental factors such as salt spray and water, and has high vibration resiliency,” Karrer said. “This unit is the ideal solution for manufacturers that require a dependable method to manage the higher power loads found in modern commercial vehicles.”

Commercial vehicle 48-volt architectures also create the potential for the mild hybridization of drive systems. Additionally, the higher power systems can be used to power electrified heaters to quickly heat a vehicle’s aftertreatment catalyst to help reduce emissions.

Learn more about Eaton’s portfolio of 48-volt solutions.

Eaton is an intelligent power management company dedicated to improving the quality of life and protecting the environment for people everywhere. We are guided by our commitment to do business right, to operate sustainably, and to help our customers manage power ─ today and well into the future. By capitalizing on the global growth trends of electrification and digitalization, we’re accelerating the planet’s transition to renewable energy, helping to solve the world’s most urgent power management challenges, and doing what’s best for our stakeholders and all of society.

Founded in 1911, Eaton has been listed on the NYSE for nearly a century. We reported revenues of $19.6 billion in 2021 and serve customers in more than 170 countries. For more information, visit www.eaton.com. Follow us on Twitter and LinkedIn.

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Contact information

Thomas Nellenbach
thomasjnellenbach@eaton.com
(216) 333-2876 (cell)