How 48-Volt Power Architectures Are Redefining the Future of Industrial Robotics and Automation

Unlocking the Full Potential of 48-Volt Robotic Power Architectures

As industrial automation systems evolve toward higher performance, compactness, and energy efficiency, traditional 12 V and 24 V power architectures are increasingly becoming a bottleneck. From my experience designing robotic and automation systems, the transition to 48-volt (48 V) power platforms is not a trend—it is a structural shift that enables the next generation of robotics, motion control, and intelligent automation.

Why Industry Is Moving Beyond 12 V

For decades, 12 V systems formed the backbone of electrical power distribution. However, modern robots, autonomous vehicles, and industrial machines demand significantly higher power density.

Power follows a simple rule:
P = V × I

At low voltages, higher power directly translates into higher current. This results in:

• Excessive copper losses (I²R)
• Heavy and expensive cabling
• Increased thermal stress
• Lower overall system efficiency

By increasing the system voltage to 48 V, current is reduced by a factor of four for the same power output—dramatically improving efficiency and thermal behavior.

Key Technical Advantages of 48-Volt Systems

The benefits of 48 V architectures go far beyond simple power delivery:

• Lower Current, Lower Losses
  Reduced current minimizes resistive losses and heat generation, improving reliability and component lifespan.
• Higher Power Density
  Compact motors, drives, and power electronics become feasible, enabling lighter and more agile robotic designs.
• Smaller and Lighter Cabling
  Thinner conductors reduce material cost, simplify routing, and improve mechanical flexibility—critical in articulated robots.
• Improved Thermal Management
  Less heat generation means reduced cooling requirements and higher system stability.

From a system-level engineering perspective, 48 V is often the “sweet spot” between performance, cost, and safety.

A Brief Evolution of Power Distribution Standards

Early electrical systems began at 6 V due to battery limitations. As electrical loads increased, 12 V replaced 6 V by halving current requirements. Later, 24 V became common in industrial control systems.

Today, robotics and automation face power demands that exceed the practical limits of 24 V. The step to 48 V follows the same historical logic—more power with less current and less loss—while remaining within globally recognized safety thresholds.

Safety and Compliance: Why 48 V Is a Smart Limit

A critical advantage of 48 V systems is that they remain below the 60 V Safety Extra Low Voltage (SELV) limit defined by international standards (UL, IEC, NFPA).

This means:

• Reduced insulation requirements
• Lower shock risk
• Easier certification
• Safer human-machine interaction

In collaborative robots and mobile platforms, this balance between power and safety is especially valuable.

48 V in Industrial Automation and Robotics

Motors and Actuators

48 V enables high-torque motors and fast dynamic response without oversized conductors or excessive heating.

Gate Drivers and Power Electronics

Modern 48 V gate drivers and current sensors support:

• Functional safety (SIL-2 / SIL-3)
• Precise current measurement
• Fast switching for high-efficiency motor control

System Integration

Lower losses and reduced cooling allow tighter mechanical integration, enabling slimmer joints, longer robot reach, and higher payload-to-weight ratios.

Autonomous Mobile Robots (AMRs)

AMRs benefit significantly from 48 V systems due to:

• Improved battery utilization
• Longer operating time
• Efficient traction and lift motor control
• Reduced system weight

In my view, 48 V is becoming the default architecture for serious industrial AMR designs.

Collaborative and Humanoid Robots

Cobots and humanoids demand:

• High joint precision
• Functional safety compliance
• Compact actuators
• Efficient braking and holding torque

48 V power architectures enable these requirements without pushing systems into high-voltage complexity. For humanoid robots with dozens of joints, the cumulative efficiency gain is substantial.

Why Not Go Higher Than 48 V?

While higher voltages improve efficiency further, they introduce:

• Increased insulation and isolation requirements
• Higher component costs
• Greater design complexity
• Stricter safety regulations

From a practical engineering standpoint, 48 V represents the optimal compromise between performance, safety, cost, and scalability for most robotic and automation systems.

48 V and the AI-Driven Automation Era

The rise of AI, edge computing, and real-time analytics is increasing power density requirements—not only in data centers but also in intelligent machines.

Just as data centers are migrating from 12 V to 48 V to reduce losses and cooling demand, industrial automation is following the same path. Efficient power distribution is now a strategic enabler of AI-powered robotics.

Engineering Insight: Designing with 48 V in Mind

In real-world projects, the greatest value of 48 V is not simply higher power—it is design freedom:

• Smaller enclosures
• Higher payload capacity
• Better thermal margins
• Easier scalability

Engineers who adopt 48 V early gain a competitive advantage in performance, reliability, and system cost optimization.