Automakers seek 42 volts from suppliers

By Brian Milligan -- Purchasing, 1/11/2001

Automaker suppliers say they are clearing the first hurtles as they try to revamp their products and stretch toward the 42-volt system vehicle.

And as the industry tries to inject some solidarity into what is otherwise a cutthroat marketplace, some are coming out now with systems that represent dramatic steps. Despite the incredible implications of a 42-volt system, suppliers are for the moment upbeat and optimistic. But there is an undeniable expectation of hard work ahead as they consider their next move, and the initiatives coming down from automakers.

"We are trying to organize ourselves for the larger challenge," admits Thomas Snyder, president of the Indiana-based Delco Remy International Inc. Delco Remy is a supplier of aftermarket and OEM electrical systems and powertrain/drivetrain products for automotive, heavy duty and industrial applications.

By 2003, most of the major automakers are going to want to have cars with 42-volt electrical systems ready to roll. They are telling their suppliers to move in that direction now. Suppliers, in turn, know what their answers must be.

"If you are a supplier, you must do this if you want to stay in business," says Dennis Virag, president of the Michigan-based Automotive Consulting Group. "If you are providing systems today with 12 volts, and you are not going to make the transition to the 42-volt system, there is no future for you ahead."

"The key point here is for suppliers to embrace change," Virag adds.

The 42-volt vehicles are not exactly expected to be mainstreamed by 2003, but in that year, several new vehicles are due to roll off of production lines. The vehicles are expected to proliferate by 2008. If things stay on track, virtually all vehicles will use the 42-volt system in about 10 years.

Suppliers like Delco Remy say the new industry standard of a 42-volt system would power a vehicle that is considerably more consumer friendly than today's vehicles, and certainly will be in demand. Higher-voltage systems will have a far-reaching effect on the auto industry. Not only does the availability of higher voltage enable advanced features, it will drive manufacturers to rethink and, possibly, redesign everything from light bulbs to major components.

Joint venture

Delco Remy now is making 42-volt alternators for the construction industry. The company is involved in a joint venture with Continental AG to create an integrated starter alternator damper for vehicles, which it hopes to have in the marketplace by 2004 or 2005. Snyder says Delco Remy has no intentions of missing out on the revolution.

"Ford and GM and DaimlerChrysler expect to introduce vehicles in the next few years," says Snyder. "We expect to be a producer in that marketplace."

Delco Remy is not alone. Some other developments are as follows:

• The Michigan-based Delphi Automotive Systems now makes a steer-by-wire system that is edging close to working with a 42-volt system. Delphi is closing the power gap with 42-volt and dual 14-/42-volt system solutions to increase electrical power and efficiency and to enable additional loads and new technologies.

• Johnson Controls Inc. and its Peer Partner Yazaki North America Inc. have designed a system that will enable automakers to easily migrate to the more complex 14-/42-volt vehicle architectures. This approach integrates underhood components to improve fuel economy and reduce emissions while supporting increased vehicle content and features. This architecture was showcased in a specially equipped 2000 Jeep Grand Cherokee.

These developments and others are coming fast for a reason. Ford Motor Co., DaimlerChrysler, General Motors Corp. and Toyota Motor Co. all are racing in this direction. All are seeking the 42-volt electrical system. Vehicles now run on a 12-volt electrical system. And with all of the consumer technology plans automakers have for future vehicles-hybrid/electrical systems, onboard Internet access and navigation devices-the system is insufficient and quickly becoming obsolete.

"Right now, the vehicle is tapped out with regard to any additional electronic content," says Virag. "The 12-vote system is delivering all of the power that it possibly can, but there is no additional power. To add new technologies you need more power plus a higher capacity electrical system."

A lot of power

If the suppliers stay on course, the vehicles that will be made from their parts will be able to brake and steer by wire. The systems will pack a lot of capability into a small device. They will be lighter, easier to run, and less expensive.

"There will be a second generation of their products at that time (2003), and anyone who is a major player in the industry will have a product that is either commercial or near commercial," says Virag.

But getting there is the trick. Virag says automakers are still toying with initiatives that will convince suppliers to speed up the process. The purchasing rewards that are being dangled can be significant, with increased buys targeted for the suppliers that get there first.

Lydia Sobo, the GM advanced purchasing engineer working on 42-volt system initiatives, makes no bones about GM's intentions. She says GM is without a doubt on the hunt for suppliers who will quickly, and cheaply, make the transition.

"Part of the GM program's mission is to identify suppliers who are working on 42 volts and begin working with them," says Sobo.

Sobo says the end result will be a more consumer-friendly vehicle. And GM's EV1 was the first recent vehicle to use components in the 42-volt range.

"We are undergoing fundamental changes in vehicle electrical architecture and 42 volts will be a part of that," agrees Dennis Wiese, GM program executive for 42-volt architecture. "The new architecture will enable some exciting advancements."

Virag agrees that the onus is on suppliers to act now, and it's not an easy task. What the automakers are calling for is nothing short of a design revolution, and a difficult one at that.

"A 42-volt system is a major change," says Virag. "It is not a simple, easy change. It's really a big step up."

"To change voltages, everything from a vehicle's lighting to charging systems will have to be redesigned," agrees Wiese. "Wiring, connectors and relays all need to change, and you'll also need a new 36-volt battery for energy storage. Even service stations and dealerships will need new equipment."

System requirements

Such a system will require new cabling, wiring harnesses, and virtually a makeover of all electrical components in vehicles. Motors, starters, alternators, relays and all power accessories for the vehicles will have to be revamped. That's why automakers are determined that the work begin now.

"Definitely, they do have to make the adjustment now," says Virag. "They have to have the facilities in place, the equipment for producing new products."

To do this, Virag says automakers are taking a two-step approach to this transition. Current accessories will use 12-volt systems while suppliers are given time to make the transition and the initiatives that may inspire them to get the job done. The second phase will come when new models adopt to the 42-volt system.

But Virag says the initiatives are being taken well by the suppliers. Suppliers, like the automakers, have a lot to gain here.

"By making a 42-volt system, you provide capability for new systems that the suppliers could sell," says Virag.

But initiatives alone won't do the job. The Society for Automotive Engineers has formed a 42 Volt Electrical System project. The project's objective is to better understand the effects and limitations of 42-volt electrical system architecture on vehicle exterior and interior lighting systems.

Part of the project is the formation of a task force. The task force was established to provide communication between the automakers and their suppliers, helping each side make the transition. The 42-volt Advisory Committee comprises 30 members of government, industry and academia. The committee includes DaimlerChrysler representative Fred Miesterfeld.

The committee is designed to encourage the development and inclusion of adequate test methods for components and systems and safety procedures in 42-volt related SAE standards. It will focus on technologies, and report to the SAE's Motor Vehicle Council. The committee will also provide liaison with international standards development and research and development activities.

"A critical objective of this proactive approach is to maintain communication with other international standards development organizations to prevent regional standards from being developed and duplication of effort," says SAE representative Jack Pokrzywa

Automakers say these efforts will help them work together to bring the vehicles to fruition. But there is also no doubt about the competition here.

"Forty two-volt architecture is an industry opportunity, not just GM's," says Wiese. "We look forward to working with our industry colleagues to develop that opportunity. Of course, once 42 volts is out there, GM wants to be the first to take advantage of it."

What the 42 Volt Electrical System Project will look at: